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Hylian Sword and Shield
The Legend of Zelda: Link's Awakening

This particular version of Link's shield and sword is not based on any in-game models or concept art. Instead these original designs were only ever seen on the box and cartridge art for the international releases of A Link to the Past and Link's Awakening. Both pieces were cast in urethane resin for lightness and durability. To begin the process of creating them, blueprints were created from the original art using vector editing software. These were then printed to scale and cut into smaller component pieces which were affixed to blocks of wood and MDF. For the sword, the grip and pommel were turned on a lathe and then further detailed by hand. The guard was cut out of two separate pieces of MDF on a band saw and then joined together. The ricasso was also cut out on a band saw. It was then shaped with a router and the Triforce symbol carved by hand. The blade itself was the only part of the sword not made from wood. Instead it was made from three thin pieces of styrene cut into the top and side profiles of the blade. An additional piece of styrene was cut to the profile of the grind. This was used as a shaping tool to fill polyester putty into the spaces between the styrene giving the blade a hollow grind. The blade was then blended into the ricasso using epoxy clay. To make the shield, a shield press had to first be constructed. Using the press, two pieces of flexible wood were laminated together to form the curve of the shield. Next, the blueprint for the shield was affixed to the laminated wood and the shape cut out using a jigsaw. The entirety of the details were then carved into the shield by hand. Finally both pieces were primed and sanded until a uniform, satin finish was achieved. They were then molded in silicone with resin mother molds for stability. After being cast in urethane resin and assembled, the back of shield was painted in a wood grain pattern using a mix of hand painting and airbrushing. The gold and silver areas of each piece were then masked and painted their respective colors. For the final steps in assembly the handle for the shield was made from heat formed PVC pipe and the leather fittings added. Both the sword and shield were then weathered using a mix of acrylic and oil paints.

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