Dragon knight Sword

Here is one (of hopefully 3) swords I'm making for Dragon Knight.

Again, with all my weapons so far, a part of this was a materials test. And I think this time I finally found the material that I was looking for. A big problem I have with the foam that I use is that it is easily dented, so I've tried:

polyurethane- cant get a thick enough layer to actually protect the foam
fiberglass resin- eats the foam like a fat kid eats cake
latex layer then fiberglass resign- yeah... didn't help

Then I looked up how people make home made surf boards and found an epoxy resign call "Klear Kote". This stuff is AMAZING! Its hard, but flexible (super flexible) and doesn't eat at the foam. So now I can just make surfboards..... that look like swords.

3 of the swords I'm hoping to do. I'll do the middle one first

I skipped taking a picture of the PVC and wood skeleton on the inside. Here is the re-glueing stage.

More sanding

I casted the little gems with another kind of resin and mixed some gold/orange acrylic with it

all put together, pre-epoxy

close up on hand guards

And the final with paint! This paint job actually took a while because I wanted a warm tone to the metal.