Big update. No real time to post, but lots of stuff has gone on with the sword. We’ve completed the mold and are going to be pouring the pieces on Tuesday and Thursday. Contact me if you’d like to come help, as it takes a lot of hands to pour one of these babies, and I’m still hunting down folks.
Above – 1st step in actually making the mold is waxing the side to be molded and then applying PVA mold release to the positive master. That gets done outside so the PVA can dry properly and quickly. Here the sword is covered in PVA before making Side A of the mold. I like the way it looks when coated with PVA, kind of like an animation or illustration it takes on a cartoon-y quality
Above – After the PVA is applied, we start brushing on resin in the booth. Once we start making the mold, we can’t stop or take a break until it’s done. Here it has one coat of resin.
Above – Can’t stop for photos, either. So after applying coats of polyester resin, three layers of fiberglass and then two more coats of resin, Side A is made.
Above – Slicing off excess resin and fiberglass from the mold. If you don’t do this while it’s still soft, you’ll be doing this later, for hours, with a grinder.
Above – Side A of the mold with excess cleaned away.
Above – Finally, mold success, or at least 50% mold success. That’s Side A in action. Now we rested the sword back into the mold, waxed everything and repeated the whole operation.
Above – Because there wasn’t sufficient sun or heat, we applied PVA to Side B in the booth. Notice the red glow of heat lamps. Notice the taped up wooden contraption it’s sitting on? That’s to keep it steady and prevent sagging, due to the size of the mold and the weight of the mold itself. That could have been a project killer, or at least a time killer, but it wasn’t too bad. Oh and remember that elaborate wooden fence I spent days building? Tore it out in seconds, as it’s purpose was done. That was slightly painful.
Above – Side B complete, ready for cleanup.
Above – How is this thing going to hold together? Bolts, lots of them. Lots of drilling. You have to go slow, so as not to blow out the backside when the bit exits. The mold is still a little soft here, so it’s easy going.
Above – Rear of the mold with the bolts in place.
Above – Mold fully assembled! We custom fit a pair of aluminum rails down the sides of the mold to prevent flexing during the casting process. The blade is so long that it might be tempted to bend, and I’m not into that. The master positive sword is still inside here, preserving the shape. The whole thing needs to get opened up, waxed and have PVA applied to both sides for the casting. Which is less than 24 hours from now. Hands and assistance for both pours are still needed, so drop me a line if you wanna come assist. It’s fun and cool, I promise.
looking good sir!