I have started work on a Thundar The Barbarian Sun Sword and I have the handle Turned out of oak. I just need to assemble it. the next big bit will be the Blade of the Sword. Any Ideas would be helpful. I can cut a shape out of clay for casting but how to light it and even how to cast it is the big Question I am faced with. I have been thinking of a system to attach the blade to the sword as well. Once I have a pic of the System I will post it till then check out my this Sketch-up sample I threw together.