As before, I sculpted the piece from plasticine:
I then boxed it in and this time I remembered the vaseline! Yay! \0/
However it made absolutely no difference. The plasticene partially stuck to the silicone in exactly the same way and had to be largely destroyed upon demolding. :/ I'm thinking it's more that plasticene isn't the best stuff to mold with. Note to self for future projects.
The mold did, however scrape clean rather well and I slush cast the hilts to keep them hollow so that they could fit around the tang.
Trouble is, the tang needs to be considerably reduced in order for them to fit and I'm concerned that this might weaken it. I think as long as it's all solid and glued firmly, the outer resin shell should help to re-strengthen it. We'll see.
Anyway, the hilt halves came out quite well. Here they are and also in situ with the blade and crossguard.
Now for a LOT of cutting, fitting, swearing, filling and sanding.
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