So, next up was the hilt. Once again, I decided to sculpt one side and cast two halves.
As before, I sculpted the piece from plasticine:
I then boxed it in and this time I remembered the vaseline! Yay! \0/
However it made absolutely no difference. The plasticene partially stuck
to the silicone in exactly the same way and had to be largely destroyed
upon demolding. :/ I'm thinking it's more that plasticene isn't the
best stuff to mold with. Note to self for future projects.
The mold did, however scrape clean rather well and I slush cast the
hilts to keep them hollow so that they could fit around the tang.
Trouble is, the tang needs to be considerably reduced in order for them
to fit and I'm concerned that this might weaken it. I think as long as
it's all solid and glued firmly, the outer resin shell should help to
re-strengthen it. We'll see.
Anyway, the hilt halves came out quite well. Here they are and also in situ with the blade and crossguard.
Now for a LOT of cutting, fitting, swearing, filling and sanding.