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Message: <blockquote data-quote="The 48th Ronin" data-source="post: 5221412" data-attributes="member: 1951">The next step was to do a little modification on the back end where it transitions into the pommel. I built that area up a bit with some Pro Poxy epoxy putty to give myself a nice smooth plug, which would help in the creation of the pommel socket.[ATTACH=full]1482736[/ATTACH]I decided to step down the very end of the plug, in an effort to minimize any significant dimensional differences between the grip w/ cloth wrap and the pommel socket (since in the comic it's drawn as one continuous contour).[ATTACH=full]1482737[/ATTACH][ATTACH=full]1482738[/ATTACH]The first step in the creation of the pommel socket was to wrap the plug with .080" diameter aluminum armature wire - this would ensure a consistent wall thickness.[ATTACH=full]1482739[/ATTACH]Then I coated it with a layer of Bondo. Once that had cured, I pulled the socket off of the plug. I brushed a thin layer of Vaseline onto the plug (so Bondo wouldn't stick to it), filled the inside of the socket with Bondo and pressed it back onto the plug. The excess squished out the hole at the back end and I smoothed that over to cap off the socket.[ATTACH=full]1482740[/ATTACH][ATTACH=full]1482741[/ATTACH]Next up was interpreting the transition into the main pommel shape. I could have tapered the socket end to a point, as it appears here:[ATTACH=full]1482742[/ATTACH]That would have been problematic however, as I imagined that the radial "petal" details on the pommel would have a definite thickness to them, which would result in a "stair-step" effect. Since the socket wasn't all that thick to begin with, the main half-circle shape of the pommel (which would be the very bottom "step") would end up being really thin, which is not what I wanted.But then there were also these shapes that looked like they could be a bit more substantial, thickness-wise:[ATTACH=full]1482743[/ATTACH]So I decided to go with something like that. After doing a line drawing to clean up the design and make it symmetrical, I cut the separate layers out of Ren Shape and styrene and stacked 'em up.[ATTACH=full]1482744[/ATTACH][ATTACH=full]1482745[/ATTACH][ATTACH=full]1482746[/ATTACH][ATTACH=full]1482747[/ATTACH]I only made one side because my plan was always to mold it and make two castings to create the full pommel.[ATTACH=full]1482748[/ATTACH]And then I made the spikes to go along the arc, also out of Ren Shape.[ATTACH=full]1482749[/ATTACH]The last step was to make the prong that extended from the pommel, and then assemble the whole thing. I stuck the pommel onto the blade to check the fit in my hand - the inner point of the blade at the end of the prong ended up touching my knuckles, so I had to flatten that side.[ATTACH=full]1482750[/ATTACH][ATTACH=full]1482751[/ATTACH]With the pommel now complete, the plan was to mold it, in order to create wax patterns for casting in bronze. However, in consultation with a friend, I was informed that the wax casting process would actually be easier if the pommel was in separate pieces (main body, socket, and prong). So I had to take it back apart, sawing the prong and socket off with a jeweler's saw.And I am now currently in the process of molding those individual pieces. So from here on out, I will update this thread as this particular project continues...</blockquote>

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