STARGATE SG-1 - Jaffa Knife

Commissioned by original produciton molds owner, i had been tasked to produce Jaffa knife replicas.

This was a early mold from the production, it’s noticeable from the way they made it, and how the silicone was soft. So it had to be taken care off properly.

This is simple but tricky at the same time, always have to apply release agent to extend life of the mold, and also demolding it very gently to avoid ripping the silicone.

I got really great result, been able to pull out 10+ casts without ripping the mold, only very tiny chunk went off, but that’s all.
This was a classic process here ;
- applying release agent (waiting 20 minutes)
- clamping the mold back together
- pouring urethane resin (waiting 1h)
- demolding

The mold had a defect, creating a curve.

For the paint, i wanted a really good metal effect ; after few researches, and thanks to Stan Winston School tutorials program, i found how they originally painted the terminator endoskull and went with the same technique.
- The cast has to be given a really smooth surface
- Priming
- Glossy Black base coat
- Clear coat
- Alclad ALC-107 Chrome

Because those kind of results take some times to do, Stargate Prop Shop wanted a “cheap” version painted with rattle can silver paint

As you can see, the silver paint doesn’t match the alclad realistic effect. In fact, Stargate Prop Shop didn’t sold any cheap version of that prop.