Bleach- Fullbring Zangetsu

Ichigo's zanpakuto after regaining his shinigami powers.

The blade is made of insulation foam covered in fibreglass and bondo. On the inside before I fibreglassed, I removed a chunk of the inside for a piece of wood in the area where the handle is connected. I ran into some problems with the fibreglassing as the first coat basically ate most of one side of the sword. I'm thinking it was because I forgot to bother with sealing the groove where I put the piece of wood.

To fix this, I ended up spraying some expanding foam which I then carved and sanded down, then added 2 more coats of fibreglass on the one side. Unfortunately it made the sword heavier than it should have been.
*word of advice: make sure absolutely everything is sealed or use epoxy resin if you can find it*

This was my first time using fibreglass mat as opposed to cloth and I regret it, much more of a pain than cloth.

The handle is simply a dowel with some ABS pipe fitted over for the ends and then wrapped in hockey tape after painting. It's connected to the sword with an aluminum rod and Gorilla Glue. For the chain(which is plastic), I carved out a slot at the end of the handle and epoxied it after the painting was done.

Normally for all my props I tend to use Krylon paints. This time I decided to try Rustoleum ones and I'm quite pleased. I might start using Rustoleum exclusively from now on. After painting, and wetsanding I clearcoated with Pledge acrylic floor polish.

The sword is about 55 inches long.