Thursday, May 20, 2010

Sword of Blight ( or me just playing around with rust…again)

After my last post about creating a rust look, I got some really good tips. So, I needed to test them out again.

I didn’t have anything handy that I wanted to look rusted, so I needed to make something. Hmm….we have a graveyard, and everything is old, undead, moldy, and decaying but not dangerous. I need to punch up the danger factor in the yard, so it’s time to arm the yard!

Months ago I took a scrap piece of wood and sanded it down to look like a sword blade. I was just playing around to see what I could do with the piece. I never planned it out or did anything else with the blade. It’s actually a little too short to look like a real sword. I also never threw it away. It’s been floating around the garage since last summer.

Well, I had some new rust techniques I needed to test out, and I didn’t want to use another boring piece of PVC pipe. So, I had a purpose for the wee little hobbit blade now.


I needed a hilt and crosspiece for the blade, so I took a piece of 1” PVC pipe and cut a slit down the middle of the pipe using a hacksaw. Be CAREFULL and go slow if you decide to do this like I did. (NOT advised). What I should have done is place the pipe in a bench vise and cut the piece. What I ACTUALLY did was hold the piece with one hand while cutting with the other. Not smart or safe. Outside I was all cool and businesslike (cause you know, that’s what’s really important, looking cool), inside I was saying, “NOT SMART! NOT SMART!” over and over. (See?!? That’s not cool on the outside.) (Yes…men are stupid, but you love us anyway!)

I think I just demonstrated the classic instance of a dumbass. I knew what I did was wrong, but I did it anyway.


Next I pried the two slit pieces of PVC apart and slid the wooden blade into the slit. Then I took the miraculous wonderment of all haunters, crafters, DIYers, and NASCAR called Gorilla Tape, and locked the blade to the pipe.

Now I needed a crosspiece. I took a small piece of blue foam insulation and cut it down to size. Cut a whole in the center of the foam, slid the foam down the wooden blade, and promptly broke it in half trying to force it over the tape.

SOoooo, I take ANOTHER piece of foam (Pink this time) and make a bigger piece with a bigger hole. This was hot glued to the PVC pipe and blade. I also used the hot glue to fill in the gap between the blade and the crosspiece’s hole. Things are looking better. Except, the crosspiece is shaped wrong and pink. I took a wood rasp to the foam to rough it up and shape it a little. Shape is decent now. Color is still pink.

So, now I put down a basecoat of brown latex paint on the crosspiece, and spray painted the wooden blade silver.

The hilt is still stark white PVC. So, I wrap the entire pipe with the black Gorilla Tape. It gives it a wrapped leather look from a distance. It looks like tape up close. Don’t get up close. smile_wink  I’ll go over the tape later with some brown and black washes to make it look more like leather. It will do for now.

Finally, it’s time to start rusting this thing up. I now have Pre-Mixed Concrete Patch and Oatmeal, as suggested by Dave the Dead and others.

The concrete patch is very nice! I spread it on the prop like peanut butter on bread. Then, I took a cotton swab and started dabbing at the patch to give it a rough texture. Next, I threw the obligatory sand into the mix and added a little oatmeal here and there. I used the cotton swab to press the oatmeal in a little deeper. I only waited a little over an hour for the concrete patch to dry, before I started painting on the rust colors. In hindsight, not a good idea. I learn a lot from hindsight. Not so much by foresight. That’s Dixie’s department.

The finish turned out ok in the long run, but it took longer to dry and every little bump would cause the concrete patch to smear and show from under the paint. I also put some of the patch on a PVC pipe and let it dry for 24hrs. I had no problems with that piece at all. There’s that damn hindsight again.

I still have to try out the Great Stuff technique that Chris Davis mentioned in my earlier post. That’s a two person job, but Dixie is leaving me for a week for Vegas. Looks like I will have to postpone this for a bit. Unless someone wants to come over and help this weekend?

By the way, I posted a How-To on this same topic over on hauntforum_logo_2 after I was asked how it was done. If anyone has some input, chime in on the forum. Here is the link to the post:


Seriously, I could use some help this weekend. The grass doesn’t mow itself you know!


Anonymous said...

Awwww, honey. I would REALLY love to stay and help you mow the grass, but DARN, I'm leaving on a jet plane!!!

Now you stay OUTTA my side of the garage this week. Don't mess with my tools, and I have already hidden my fancy Xacto and the good Dremel. Be good boy. ;) hahaha.

I really love the rust you have going right now, of course you know that.... and I can't wait to get back and start rusting 1400 sections of fence, a column arch, some more weapons - in order to arm the yard - and maybe even the dog. Bear might look good rusted. ;) 01010101

suzanne said...

Your sawing technique is exactly the way I would have approached it. Proof that you don't have to be a man to be dumb. ;)

Good to see that it turned out well in the end.

William Bezek said...

Nice looking rust, who knew breakfast food could be spooky!

Chris 'Frog Queen' Davis said...

LOL! You and Dawn just crack me up (I totally mean that as a compliment!) This came out great! Very cool experiment. I have a few real swords in the house....up for playing 'sword fight'? :D

Thanks for keeping us posted. When we do some rusting, I will post pictures also. Thanks for the inspiration!



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