I checked the prototype, and the glue I had used is still not cured in some places! That's what I get for using too much, and not taking the time to do it right. I had to use my cell phone camera again for these pictures. (I really need to get a camera for myself!)
I will continue the construction method I first devised, a dowel spine and the blade made of two halves of polystyrene insulation. As with the prototype, I used a dremel to route a channel for the spine, but I made it by running two passes right next to one another, ending up with a channel that was 1/2" wide by 1/4" deep.
Next, I ran a bead of glue down the middle of the channel and inserted the dowel rod into the channel. I'm letting the bead of glue cure before I put the other half of the body on, to make sure that it cures all the way. Here I've clamped it with the new clamps I bought. I had to use come scrap material to extend the reach of the clamp jaws.
Here is a close-up of the dowel in the channel. I only used a small amount of glue, so hopefully it will be cured by tomorrow, and I can sandwich the pieces together Friday night., then on to shaping the blade and defining the edges, hilt and grip on Saturday!
That's all for now, I'll update more when I get more done!
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