For this project I wanted to try sintra as a main material for the construction of the blade. It turned out really well. Automotive paint and products were used for the finish. And at this point I just to need to wrap the handle in leather.
Specs: Total length 60in. Blade length 40in. Hilt to pommel 20in. Blade widest point 4.5in. Weight 3lbs. Labor hours 17 hours (in 4days) Materials: sintra, cast resin, dowels for the core, pvc, body filler, primer, urethane bases and clear
sintra is also known as expanded pvc foam. is a plastic, it comes in sheets. easy to shape, you can heat form (safely) and well... since its a plastic it takes paint really well. I substitute wood with sintra when i can.