Local-ish Caster Wanted (QLD 4020) for Sword Copying Project

Hi all, I have been asked to help out on a project which I was initially going to do in polyurethane with a plaster mold.

Looks like it isn't going to work in that material.

The Project:

Cast an antique Japanese samurai sword, katana, so that the copy can be sent overseas to have all the furnishings custom made.

The sword blade is in good condition but the scabbard, handle, hand guard and other fixtures and fittings all need replacing.

Sending the original overseas is a risk that the owner does not want to take.

If I can get an accurate cast of the blade in a lighter metal then that can be sent abroad instead.

The guy is super keen on getting this done before his trip to Japan in March.

I explained that it was going to be very expensive in polyurethane and he wasn't concerned about the cost. I suggested that it would probably be more in aluminium but he actually liked the idea of having an aluminium replica more.

Questions are.

Is this doable? The problem with polyurethane is that being long and thin the cast would deform easily. Would other metals (not necessarily married to the idea of aluminium) hold up better?

I sent of a couple of inquiries to a local non ferrous foundry but I haven't heard back from them so I guess they are not interested.

Are there any hobbiests who would take a crack at this project?

Happy to do all the leg work and obviously cover expenses in material and time.

Thanks for taking the time to read and consider this request, if you can help in any way it would be much appreciated.

Mark


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