Oh, Hi there Clariel!

Sorry this post is a little late. I got lots of pics for you. Forgive me?

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Last week was a flurry of painting, engraving, sculpting, sanding, gluing, sewing, and spraying. I think it was worth it.

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You might be able to see a slightly different “texture” to the surface of the blade than previous carved models. That’s because I’ve added a UV-resistant spray (several coats!) to protect the resin and leather from fading or yellowing in the sun, and also to protect the resin from scratches.

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Still just as see-through though! ^_^ So what’s next for this sword? I got my shipment of push-button switches yesterday evening and today I’ll be toting them to the workshop. I’ll be designing the interior circuitry for the lighting. I’m sticking with the concealed light switch design (that’s the plan anyway) to give the illusion of magic.

Well, writing about it isn’t going to get it done so off I go to the workshop! Wish me luck.

Making Some Magic

Hi everybody! Just a quick update to let you know I’ve got a couple swords all polished up and ready to be fitted with handles. One more is awaiting polishing.

After this step, I get to wire up the electronics for the lighting and then they’ll be ready to be sold. Yay!

Some Progress?

Okay! Good news: I’ve completed one half of the silicone mould for Clariel and about 1/4 of the other half. (It’s a two-part mould.)

Bad news: I’m out of silicone and my supplier still hasn’t delivered my shipment yet. Rrrrrgh! Come on! I ordered it back on December 22nd! Get the lead out guys!

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Not half bad if I do say so myself. Uh, no pun intended. The silicone looks a bit tacky and weird on the surface in this shot but it’s just because it has mould release painted over it. I need to be verrrrry sure that it will come apart when the top layer is finished curing, otherwise, my sword will be trapped in a solid block of silicone. That would suck.

Now, hopefully, I will get to work this morning and find that my new silicone shipment is waiting for me. Wish me luck everybody! I’m trying my hardest to make this happen!

Final Moulding: Clariel

Hey guys! I am really excited and nervous today. I’m using my brand new vacuum pump and taking the final mould for the Clariel model sword. (I hope.) It has taken way longer than I thought to get that plaster sword prototype as smooth and shiny as I possibly can.

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The glossy varnish I have needs about 12 hours to fully set before I can put on a second coat so you can imagine how long it took to get multiple coatings on and then polish the thing.

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I think it was worth the extra effort. 🙂

Now, the next step is getting it fitted into the moulding box nice and snugly. That took a long time as well. Why? Because you saw how sloppy my first mould was. Let’s not have a repeat of THAT nonsense! We want the two halves of the mould to line up all straight and smooth and beautiful so that I can easily clamp them together with no leaks or weird seams.

To do that, I have to find the exact middle of the object I’m taking a mould of. That’s tricky when it doesn’t sit flat on the table. It’s chubbier in the middle than it is at the point of the blade or the pommel (butt end). So that makes it do a see-saw thing when I try to lay it flat. To compensate for that, I have to put a cushion of clay under the blade and the handle to make it sit perfectly level. Then, I have to cut a piece of laminated foam (or anything else that’s flat really … could be wood but I used foam) to fit in the space between the sword and the edges of the box. That’s so the silicone doesn’t fall down through any gaps and fill the whole darned box. That would trap the sword inside and I’d be really sad. (Hey! Give me my sword back!)

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And that gives us exactly one half of Clariel to make exactly one half of a mould. Yaaaay!

But what’s all that green stuff in there? No one said there would be green stuff aaahhhh! Don’t worry. that’s just clay. Some of those clay noodles are touching the sword and some aren’t. The ones that are touching Clariel are air vents. Those allow the bubbles to escape from the resin when I pour it into the mould so (hopefully) they get out of the sword and don’t get stuck in there.

The noodles that aren’t touching the sword are what we call “findings”. You know when you’re closing a plastic container of leftovers and putting it in the fridge for later? Take a look at the lid sometime and you’ll see there’s a trench all the way around where it fits over the edge of the container. That makes a nice snug fit so air doesn’t get inside and so you know the lid is in the right spot before you push down on it for that nice satisfying “click!”. Container closed and ready to go. Like your plastic sandwich box, the two halves of the mould need to fit together nicely and the findings help you figure out when both sides have lined up just right.

And then I pour 300 Euros of silicone into it. Haaaaah … yeah send me Luck runes guys! You can probably see why I’m a little nervous of screwing up! Haha!

Well, that’s enough procrastinating for me. I’d better go Iron Brother it up in the workshop. (I’m just kidding. I love talking to you guys. LOL) Oh, and if you’re a Matthew Daddario fan like me, don’t forget to wish him a happy birthday if you haven’t already!

Ciao for now!

Clairel: First Moulding

I started writing this post yesterday and then realised I didn’t have a picture for you! Durrr … That’s not nearly as exciting without a pic.

So you can see my first Clariel prototype (carved in foam) in there, covered in latex and ready for its hard casing to be put on. The casing is already on there now but I forgot to snap a photo before I left the workshop yesterday. (Cause I’m brilliant like that. XD )

I’m really hoping I did everything in the right order. BUT if I didn’t, it’s okay. I can always do it again.

Remember: if you failed but you learned something, you haven’t wasted your time!

Clariel Model Prototype

Ahhh yeah. It took me a couple days to carve the prototype for Clariel. Now I can take the first mould of it. After that, we move on to the second prototype which will be made of plaster. I’ll be able to get a much, much smoother surface with higher detail with plaster.

Also! Special news!

I’m moving to a new workshop! Don’t panic. It’s in the same building on the same floor so it won’t take long. Probably a day or two. This new room is a bit more expensive but it’s also a bit larger and has a couple windows.

I decided to take on this added expense for the sake of having a window so that I can have fresh air and natural light to work with. Alumilite is a very low-smell resin but it’s still recommended to have fresh air when working with it. I’ll post pics as soon as I’m able.

Until then, stay safe out there Shadowhunters.

Forgot to Say I Went on Vacation Whoops!

Hi folks! I logged in today to say I’m back from my trip to Canada and realised I didn’t make a post to say I went away in the first place. Duuuuuh good job Ethan. XD Sorry about that everyone.

To the people who have been waiting patiently for me to get back to their emails, thank you so much and I will respond as soon as I can. I’m still really jet-lagged and I want to give you a response when my brain is actually working.

The finger I accidentally chopped is healing up nicely. I still have a lot of numbness in the tip of it but the feeling’s gradually coming back. There’s one spot that’s rather sore that I think I damaged the nerves there. Feels kind of like when you bang your elbow on something whenever it touches a hard surface the wrong way. Typing is still annoying but getting better slowly.

Even on vacation, I was still thinking of y’all. In fact, I spent an afternoon chattering with an engineer friend about manufacturing. He also does resin casting and moulding projects though on a much larger and more industrial scale than me. But whether you’re casting machine parts or art, it’s the same principal.

In short, I got some really valuable knowledge on rapid prototyping, moulding, casting, saving money on my development stages while still producing quality stuff. He wants to have a look over my sketches and schematics as I launch into resin casting my swords so he can give some feedback as I go.

To tell you the truth, it feels great to have a bit of practical support in this crazy endeavour of mine. I don’t need much. Just an occasional glance over my shoulder and a comment or two steering me away from pitfalls and letting me know that there’s an easier way to do something. I’ve been doing this alone for more than two years now and it’s been hard. It’s been lonely. And I’ve had to learn everything the hard way by trial and error. But, like the Iron Sisters, I’m too stubborn to give up.

“A Shadowhunter must behave as though victory is assured,” as the Codex tells us, and I haven’t forgotten that. Quitting is not an option for me, and never has been.

What’s coming up in the near future? You can expect to see in-progress photos of my planning, prototyping, and casting phases as early as next Monday. I’ll be answering your emails as early as today. I will be continuing development on witchlights and steles and you can expect to see my progress on that too. (So far I’ve got silicone boogers that were not the density I wanted so I’ll be making resin versions of the witchlight instead. LOL )

After I’ve moulded and cast a Clariel model I’m satisfied with, I will be putting up a poll for you to vote on the next model to be put into production. I have a feeling I know which one it’s going to be but I want to hear from you all! Your input is my guiding light and steers what I create in my workshop.

As soon as I have a reliable system of production, I will be putting up an Etsy store for a much easier ordering process. So far, I’ve been hiding out in this remote corner of the internet because I’m totally overwhelmed by orders as it is. XD Once I know that I can keep up with demand, I can put my fuzzy face out there for all to see and get Seraph Blades out to all the lovely Shadowhunters who need them.

Before I trundle off to the workshop, I want to let you all know that I’m so very grateful for your support. The emails and comments that pop up in my inbox every morning put a smile on my face and remind me of what all this work is for. I feel super lucky to be making cool stuff for other Shadowhunter fans. You inspire me to create, forgive me when I screw up, and give me courage to keep going when the going gets tough. We have such a great fan community. Love you all. ❤