Project updates

Finished up

I finally finished the mask this weekend and I’m now happy that it as symmetrical and smooth as I can make it. Next up is to order another batch of silicone to recast it and make a few copies.

I also got close to finishing my scabbard, which only needs a little more sanding and filling before painting.

Lastly some of my time was taken up with an issue with one of my 3D printers when it got blocked. This occurred just above the nozzle in a gap that I was unable to reach and pull out. Due to this I attempted to drill out the plastic with a small bit This seemed okay at first but I must have drilled to far and the end of the nozzle cracked. I have now had to order a new one to replace it. I can then get back to using both printers to produce my sword.


Sand and fill

I was away at the end of this week and only managed a bit of making.

I began by assembling the parts of my sword I had printed so far including the pommel and grip (not in picture). Any parts that hadn’t been sanded were done and the gaps were filled. I did the same with the scabbard, which hopefully I should be able to finish next weekend. Having sanded and sprayed the mask, I noticed a one last issue – the right eye socket was slightly off. This was fixed with some 2 part putty, when this has been sanded it should be done.


The week of making

This week has been a holiday for me and I have spent a good amount of it being creative and working on various projects.

At the end of last week and the beginning of this one I finished modeling a sword I

At the beginning of the year I doodled some sword designs in a sketch book. It think there were about 8 or 9 in total. I wanted to make one of them but couldn’t decide which to do and so asked my friends which I should make. Below is the one that was most popular, now referred to as sword 8.

Sword 8

Rather than Balsawood and worbla I chose to go with 3D printing. At the end of last week and the start of this one I modeled the design and broke it down into parts. I also add a space inside the sword to slot in a 4mm/1metre rod for added strength. With the design finished I have begun printing off the parts and sanding them between working on my other projects.

Getting distracted by a new project idea seems to be one of the problems I’m encountering a lot recently. An example of this is when I watched a video from Punished Props which came out on Monday. This video is a tutorial on how to make a foam skull from Sea of Thieves, which has a downloadable template available. Well I couldn’t miss this chance to try something different and ended up making one. Mine didn’t turn out quite right, but I had lots of fun making it, plus I finished it and can carry on with other things. The video is below if you want to try your own.

Work is almost done on the Sith mask having done all but a bit of the filling/sculpting. It just needs a bit of sanding and it should be ready for casting again.


Straight Sword

This weekend and the last were mostly spent on trying to complete the Sunlight Straight Sword. This was going pretty well until I started to get bubbles on the surface of the sword. Not 100% sure how these occurred, but it may have happened between layers or from friction: these only became visible when I applied some Rub and Buff to the sword.

So I went back and sanded the blade section back down and filled any bubbles after popping them. I was also concerned about the amount of  marks I was getting as the Gesso is a little soft. To prevent this I mixed up some resin (XTC 3D) and applied it with some cheep sponge brushes – this is a great way to apply it to a flat surface. Not sure why I didn’t try it before as it minimizes the brush marks and therefore sanding. After three coats I sanded the resin lightly using 180, 400 and 600 grit sand paper. This gave a beautifully smooth finish and no bubbles in sight. So I used the Rub and Buff again and got 2 bubbles GRRRRRR 😡

Although previous projects using Gesso coat have come out okay, following this, I’ll only use resin coats in the future.  Although they can take a little longer to dry (4 hours each layer), only 3 -4 coat are needed, the finish is more durable and smoother. This along with the Rub and Buff gives an almost mirror finish to the blade. Overall, apart from the bubbles, I happy with the way this turned out.

Next up I will be finishing the scabbard (using resin coats) and the mask I have also been working on.



Oooooo Shiny


Annoying bubble


I began this weekend working on my sword and scabbard, doing some further sanding and filling. Annoyingly the temperature dropped and it snowed again. This wouldn’t normally be a problem but I used some filler that is best sanded outdoors. Maybe I can finish it next week.

I did get around to completing my Sonic Screwdriver, tidying up the paint job including using some liquid silver leaf on the tip. I then gave most of it a coat of varnish. Hopefully my friend will like it.


I also worked on and finished another sculpture over this week. I was inspired to do this one after watching an episode on the Drawfee You Tube Channel.  This can be watched below if you are interested.

Lastly after having some difficulty finding some belts I liked for my Soliare costume, I decided to try and make my own. These are going to be made from some faux leather, glued and stitched/riveted together.


March 1

I don’t really have much to show this weekend, as it has mostly been spent sanding/filling the sword. Though I did model and print some D-rings for my scabbard, attach them and begin coating it with gesso. Plus my Sonic Screwdriver is almost finished and I’ll try and post a image up soon.


February 3

I didn’t post last weekend as I had hurt my foot at the end of week and had to rest it for a few days. While I wasn’t able to do any work on my projects for a few days, it was my holiday, so I had the rest of the week. Due to this I wasn’t able to complete the sword and mask as planned, but I did move them closer to completion. This post will be a little longer than normal to cover all the projects I worked on during my week off.




I continued to sand the plasti paste coating down until I was happy with it. What I wasn’t aware of was that this product contains LOTS of tiny fibres. When I had a close look, the blade looked as though it had a day or two growth of  stubble :-/  Never mind, this was to give it some more strength. To combat this I gave it around 8 coats of Gesso paint over a few days. When these were fully dry I sanded this down as smooth as I could, before giving it more coats. Following a few more rounds of this it should be nice and smooth and ready to paint.

Between coats, I worked on three other projects: the mask, Sonic Screwdriver and a scabbard for the sword.


After doing some research on how  they are made and finding an in-game reference image, I constructed mine from some spare balsa. As with the sword this was given a covering of worbla. Since it is a nice sturdy box it won’t need anything over this. When I have worked out the belt attachment points I’ll cover it in Gesso and then paint it.


Sonic Screwdriver

I wasn’t happy with the way the previous one was going and re-designed the parts so they could be printed whole/slot together. This would mean that the parts wouldn’t move as I originally wanted, but I was okay with that. The prints turned out really well and after less sanding than I thought they would need, I glued it together. All the parts are sprayed and I’m hand painting a few details before I weather it.



The mask was also sanded but I wasn’t happy with one of the eye sockets. Putty was sculpted onto this to make it more symmetrical as well to some thin areas on the back. It will need some more work and sanding before I’m totally happy with it.

Finally,: remember to look where you’re going and don’t accidentally kick metal gates while moving boxes.

February 2

This week I took a good step closer to actually finishing another project. During the week I added more silicone to the mould of the Darth Nihilus mask and today I managed to cast a copy in resin 🙂



This is the first slush cast I’ve tried, though I did use Smooth Cast 300 resin which is probably not the best for doing this. Even so, I am happy with the result. There is a little bit of sanding needed despite my attempts at  smoothing the clay, as well as a little bit of filling. When this has been done, I may re-cast the finished mask and do a few copies.

While things were drying I also did some more work on my Sunlight Straight sword sanding/filing and filling gaps. Although the Plasti Paste coating works well, it is an effort to file because it keeps gumming up them up. If I make another sword this way I think I will use something else.

I have a weeklong holiday coming up soon, and I’m setting my-self the target of finishing both the mask and sword. Both are getting close and this should be an achievable goal.

February 1 (or covering stuff)



As the tile suggests, this weekend I has mostly been spent covering things I have made with various chemicals.  Earlier in the week I ordered a Smooth On brush-on- mould making kit. This box contains silicone, resin, plasti paste II, resin thickener and mould release. I managed to pick one up at a reduced price, but even at full price one of these is a real bargain on buying everything separately.

20180204_152530Sunlight Straight sword

Last week I planned to cover the sword in resin to give a hard, smooth finish. When I got the pasti paste I began to wonder if that might work and decided to experiment. Since the container has more in than I would need to make a mould casing for the mask, I mixed some up and covered my sword in it. When this dried it sanded really well; although it does gunk up sandpaper and files. I’d recommend just using files initially and cleaning them to save on sandpaper. The sword has now been given a second coat ready for next week.




Darth Nihilus Mask

Now the silicone had arrived I began making the mould on my mask. I didn’t manage to finish it this weekend, but will add more layers over the next few days. This may then be ready for casting next week.

Other projects

I didn’t have time to mould the sword grip for the Thor sword this week and may leave this until the mask and other sword are finished first. I may also attach the blade to it and cast it all in one go.

My second prop hammer has now been painted.

It is great to see these projects getting a few steps nearer to completion.

January 4

Most of this weekend has been spent working on the new sunlight Straigtsword I started last week. Following on from it’s resin coat, yesterday I added a layer of fibreglass. These two layers and the worla covering today have made it pretty sturdy, while maintaining some flex. With the whole sword now covered, I’m going to spend some time tidying edges before working on getting it smooth. While it didn’t work for smoothing last time, I’m going to go with a different resin on this sword – XTC 3D. This is normally used for smoothing 3D prints and I’m interest to see how it works on flat surfaces.



The grips/hilts of the Thor Sword are now ready for casting. I plan to order some silicone to cast it along with some different stuff to do the mask next week.

The new foam hammer is nearly ready and I’m just waiting for a layer of paint to dry before I finish it off.

Finally, I have been taking part in a month long art challenge and wanted to share a drawing I did. The challenge for the day was to draw yourself as an animal. This is me as a fox in a rare moment of lounging around.