Hi guys, looking for a little help.
I'm making a prop sword cane, and shooting to make one convention friendly. Having a real metal blade is the easy route, but wouldn't pass muster if it ever came to that, and honestly I'd prefer not to have a potential real weapon on me in those places.
So, I need a one off blade that is about 29" long, 1/2" wide, and 1/4" thick. This includes what goes into the handle to secure the blade.
I am mostly concerned with methods for casting something so long and skinny that won't be flimsy or break easily. It needs to stand up to abuse. I have a bunch of epoxy resin and fiberglass supplies handy, but am willing to acquire other materials needed (and am not worried too much about cost, I hate working with the cheap stuff).
I made one attempt at it by creating two half molds out of fiberglass (cut 1/8" thick piece), and then pressed them together. I'm thinking at this point my best bet might be to just patiently layer epoxy resin and thin strips of glass until I fill each mold, then with enough resin to make sure it's full press it together. I don't care if I need to do filler work at the end, I just need a shape and strength.