Fill Sand Fill Sand Fill Sand Fill Sand.....
The crossguards needed a LOT of tidying up. If I'd had the resources, I might have polished up one and then made a new mould from that so that I'd get two clean casts that didn't need tidying. Unfortunately, I was out of silicone and so I had to spend a great deal of time filling, spraying and sanding until the surface was glassy smooth - or close enough, anyway.
I then spent a week or so doing bits here and there.
The main bulk of the sword was assembled and filled in.
I still needed to add the decorative leafy bits. After that it's time to tidy and polish before
One thing I didn't forsee and should have, really: It's HEAVY!