So I started out with two wooden dowels, and after gluing them together (and adding resin for some extra support) I took two long sheets of fiberglass cloth, resined them, then glued them to both sides of the dowels. What you see in the above picture is the "mold" I made. I cut the two sheets of cloth to a shape that closely resembles the Master Sword, used about a half of a roll of masking tape to seal it off, and then simply started pouring resin in.
This, and the picture below, are what you get.
Then, it was a simple matter of taking the dremel, and grinding out an edge. I made a mistake, and forgot to add in guidelines, so the jagged edge you see below is the result of me trying to just eyeball it.
Fortunately, the Goddesses of Hyrule saw fit to bless me with the wonderful putty known as Bondo. (Or body filler) Which is wonderful for covering up mistakes, and holes, and pretty much everything I did wrong haha.
First world problem: That time between applying Bondo, and waiting for it to dry.
This is the blade (and it's edge) around 90% finished. Most of the uneven-ness has been taken care of, and it was just a matter of filling in some little holes, and sanding them smooth.
Now for the hilt! For the hilt of the Master Sword, I simply just used the same process as before (sorry, I forgot to take photos during this process). Two sheets of fiberglass cloth, glued to the dowels, cut out to the desired shape, then masked off and filled with resin.
This here is me marking out the details for the hilt. Specifically the globe at the base, and the "wings" that form the crosstrees.
With luck, I'll be able to finish this come the end of October. Hopefully once it starts to get cold I'll have an indoor shop to work in.
More updates soon to follow!
