Silicone Sandwich

Otherwise known as the two-part mould. It’s half finished guys! Actually, it might be all finished right now; I have to go to the workshop to check. But I wanted to share with you the progress shots from last week because playing with goo is exciting!

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There’s the mould design sculpted in clay.
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And placed in its box for silicone pouring!
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Some kind of strange Ikea cake …
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Now to clean of allllll that clay. It took hours.
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Then a quick re-sculpt of the spout and air vents.

And it was all ready to go back in the box for the second half! Then I hit a few snags. First, since it’s the other side, the bendy part around the blade had to be put on the other way and when I did that, it somehow ended up about one centimetre shorter. I have no idea how this happened. Oh well! I just added some more corrugated plastic on the end.

Then, I noticed that the straight pieces of foam board I had used for the upper parts of the sword had become badly warped overnight! I tried to patch the gaps with extra hot glue but it just wasn’t working. I had to cut some MDA board instead and use that. That sucked up some extra time.

Then, as I was degassing the silicone for the second pouring, I realised something: it was really hot in my workshop. I thought it couldn’t be more than 24C or so in there and I was really focused on my work, not my comfort. BUT, with this silicone you can accelerate the curing time by increasing the temperature. Handy right? Except when all the bubbles aren’t out of it yet and it’s starting to set! AHHHHH! By the time I noticed what was wrong it was already as thick as cookie dough. I had to stick my gloved hand INTO the bucket of silicone and pull it out glob by glob. It even started curing to my glove and I had a big hand-sized blob of blue slime dangling off my fingers as I desperately waggled it, trying to get it off. It eventually plopped into the mould box with the rest.

So … will it be okay? I don’t know! The top of it won’t be as smooth and glossy as the top of the “Ikea cake” picture there. I’m afraid the silicone had already thickened so much that the last blobs that fell in will probably stay as they are and make the surface bumpy and weird. What does that mean for me? Well, it just means that I’ll have to do a fibreglass jacket around the mould instead of a wooden clamping box. Oh well! I have the stuff to do either one and I was on the fence about which way I wanted to do it anyway.

The real question is: did it cure nicely against the SWORD? Because if there’s bubbles or spaces against the sword, I have to do this part of the mould again. I’m making a pretty new mother mould for every Clariel model sword that will come from my shop. If there’s a mistake in that mould, there will be a mistake in every sword it produces! And I’ll have to take time to fix each and every one. That would ruin the point of making a better mould in the first place! It’s gotta be just as perfect as I can possibly make it.

Wish me luck! I have a feeling I’m gonna need it today.

New Mother Mould

Hi everybody! Quick update to let you know what I’m up to. I’m setting up the moulding box to pour the first half of the new Clariel mould. Yay! It doesn’t look too jazzy right now but cool stuff is coming.

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Why the new mould? Well, after casting 4 swords from the first mould I made, I realised that each of them had a slight bend toward the right near the tip. This was easy enough to correct with a trip to Chewy (my belt sander), but I didn’t want to have to do that for every single sword. That makes a lot more work for me and takes too much time to produce each sword. I’m working on getting high quality swords made for you faster so that more people can have access to the pretty stuff. Anything that stands in the way of that goal is simply no good!

So I went back to the plaster model sword and shaped and measured it with more accurate tools. Then I carved a light slot into it so I don’t have to do that freehand with each sword I make. (That saves about an hour per sword.) Then I re-finished the whole thing with several layers of sealant and gloss and buffed it all up to 2000 grit. My aim? To get it as smooth as possible so I have the bare minimum of sanding and polishing to do to each sword that comes out of the mould.

Well, off I go to the workshop! Wish me luck.

Quick Update & A Lot of Pics!

Hi everyone! I’m in a bit of a rush today. Lots of running around picking up materials, doing research for tools I’ll be needing in the near future, and trying to get the last bit of work done on the Clariel model sword to create the final perfected mould. Gah! It’s crazy!

And 25 degrees is WAY too freaking hot for me! I’m melting. Seriously, I moved within sneezing distance of the Arctic Circle to get away from being toasted by the evil fireball in the sky …

Stop talking about the weather and give us pictures already Ethan! Okay okay. Yesssss I finished the 2nd cast resin Clariel last week and she is awaiting word from her Australian Shadowhunter to ship out. Here’s the pics I promised.

Shiny in the suuuuun! ๐Ÿ˜€

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Ahh you runed it! Haaaah terrible pun … *ducks head in shame*

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I’ve been working on getting my rare-earth magnet closures smaller and tidier for a nice sleek look. How did I do guys? ๐Ÿ™‚

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Oooooh shiny! Yes it’s in my sauna. LOL I currently have nowhere else that is dark enough to show you the full glory of the sword lit up. But you know what? I’m rather proud to be living and working in Finland so I think it’s kind of fitting that the quintessential Finnish element of the sauna plays a role in my work even if it’s a small one. ๐Ÿ™‚

That’s it for me for the day everybody. I’ve got to get going. There is SO much sanding and polishing to do and OMG I almost forgot!

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This one. This one is not yet claimed! If you want this Clariel for your very own, I have an Etsy listing for you to pounce on right HERE. And since it’s not yet finished, YOU get to choose what kind of finish you want to have on it. Lit? Unlit? Runes? No runes? Some runes? Different runes?! It’s up to you. Your wish is my command! ๐Ÿ˜‰

Have a great day everybody! I’m off to … everywhere, probably all at once. LOL

Second Clariel

I’m so excited guys! I’m almost finished the second cast resin Clariel sword and it is gorgeous.

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The handle is all painted to simulate the look of weathered steel and the whole thing has been given three layers of high-gloss sealer. This sealer protects the sword from scratches and the yellowing effect that UV rays can have on resin over time.

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I’m committed to making items that stand the test of time so it’s very important to me that each sword has adequate protection against wear.

All that’s left to put on this sword is the handle strap and it will be ready to go to its new home! This Clariel is promised to a lucky Shadowhunter alreadyย but the 3rd resin cast Clariel is still unclaimed! Will it be yours?

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