Update, Assembling and Priming Models: Expert Prep Hacks

Crafting a life-sized replica of the Hessian Horseman Sword from Tim Burton’s Sleepy Hollow, has been one of the most exciting projects I’ve worked on. As someone who has spent over 35 years painting miniatures and recently ventured into designing my own, I love sharing the challenges and rewards of assembling and priming models. This time it is even a more exciting project because it is the first time I am doing a 1 to 1 scale life replica from scratch. Whether you’re a seasoned hobbyist or just starting, I hope this guide helps inspire and inform your journey.

“Discover the art of 3D modelling as we recreate the iconic Hessian Horseman Sword from Sleepy Hollow. From inspiration to creation, see how dreams take shape!”

An Update on the Assembling and Priming:

I was hoping to have every part of the Sleepy hollow Hessian Sword ready for painting but personal life and bad weather, yes bad weather made it so that I could not manage to fulfil my plans on the Hessian Sword for this week.  I hope to be able to find some time and manage to complete this work by this week even because I will be away for a small weekend break with my family next week.

So why I you mentioning the weather and the bad effect that it had on your prepping work and what does all this have to do with Safety?

Safety First: Staying Protected While Assembling and Priming Models

Why Safety Matters

The prep work for assembling and priming models involves tasks like sanding, applying putty, and spraying primer—all of which can produce harmful dust and fumes. Here’s how I prioritize safety for my health first because if health comes less, I would not be able to do more projects in the future:

1. Work Outdoors if Possible when Assembling and Priming Models.

Fine dust from sanding can linger indoors, spreading to areas where it can harm your family. I do all my sanding and priming on a designated section of my roof to ensure proper ventilation.

2. Use Protective Gear

• Respirator Mask: Wear a certified mask to protect against dust and fumes.
• Gloves: Epoxy resin and car putty can irritate the skin, so gloves are a must.
• Safety Glasses: Prevent fine particles from reaching your eyes.

3. Keep Clothes Separate

The dust from sanding can cling to your clothes, making you a carrier. Use old clothes specifically for this work and wash them separately.

4. Shower Immediately After Work

Fine dust particles can stick to your body and hair. Taking a shower prevents these from spreading around your home.

Pre-Assembling the Hessian Sword – Update of works

The Hessian sword is now officially composed of 2 separate parts (which will be joined in one at the end of the painting phase).

Assembly:

• Handle Assembly:  was quite straight forward.  All 3 parts had excellent fitting areas in between them and it was just a matter of a bit of test fitting and use of adhesive epoxy resin to unite them.  Once the epoxy was dry, I fill in the gaps with putty and sanded it.  A priming layer of white helped to spot and correct eventual defect.  Once done I gave a black undercoat and a silver base paint to have it now ready for paint.
• 

  Joined handle and primed black – building the 1 to 1 scale sleepy hollow hessian sword at dressart3d.com

• Blade Assembly: Joining the four blade parts required extra attention to ensure perfect alignment. A full guide can be found in my previous blog article.
• 

  prepped blade before undercoating building the 1 to 1 scale sleepy hollow hessian sword at dressart3d.com

Using Epoxy for Strong Connections

I used Gorilla Epoxy Glue for assembly because of its strength and durability.

• Apply epoxy generously to the joints.
• Align the parts carefully on a flat surface to ensure they stay straight.
• Allow 24 hours for the epoxy to cure completely before sanding any excess.

Mastering Seamless Assembling and Priming of  Models

Joining the Blade Parts

Aligning and joining the four blade segments was the most challenging step.

• I worked in pairs, joining the top two parts first, then the bottom two.
• After curing, I sanded the connections before joining the two larger sections.

Sanding for Perfection

A flat surface, like a tile or wooden board, helped maintain the blade’s straight edges during sanding. Repeated priming and sanding ensured a seamless, flawless finish.  I had some trouble aligning the connection between the blade’s fuller lines but a generous amount of epoxy resin applicating and sanding to the correct line alignment solved the problem even if it required quite some hours of work.

first white primer coating building the 1 to 1 scale sleepy hollow hessian sword at dressart3d.com

Priming the Assembled Sword

Why Priming Is Essential

Priming not only enhances paint adhesion but also reveals surface imperfections that need fixing. I used white primer for this project:

• It highlights defects that might be missed on bare surfaces.
• Thin coats allow the intricate details to shine through.
• 

  final base coat of silver for the handle – building the 1 to 1 scale sleepy hollow hessian sword at dressart3d.com

Fixing Defects After Priming

After the first primer coat:

1. I inspected the model closely for imperfections.
2. I used car putty to fill gaps and fine sandpaper to smooth rough spots.
3. I reapplied primer to create a uniform surface.

Current Progress and Next Steps

What’s Done So Far

• Handle Section: The snake head pommel, handle, and cross guard have been assembled, primed, and undercoated in black and silver.
• Blade Section: The four blade parts have been joined and primed, with defects corrected through sanding and putty application.

What’s Next?

The sword is nearly ready for the final paint phase. I’ve also created a special additional element for displaying this piece, which I’ll reveal soon.

Explore Unique Creations at DressArt3D

If assembling and priming models like this seems overwhelming, why not check out our collection at DressArt3D.com? From professionally painted miniatures to unique t-shirts and other merch, we offer one-of-a-kind creations for collectors and gamers alike.

Pro Tip: Support our projects by purchasing from our store. Every sale helps us bring more exciting builds like this to life!

Have questions or feedback? Reach out at contact@dressart3d.com—I’d love to hear about your projects or offer tips to help you succeed.

Final Thoughts

The journey of assembling and priming models is as rewarding as the final product itself. It’s a process of patience, creativity, and sometimes, overcoming unexpected challenges. With the Hessian Sword nearly ready for painting, I’m excited to see it come to life. Stay tuned for the next article, where I’ll share tips and techniques for painting this masterpiece.

3D Model

The model is also available as a 3d model.  Contact me contact@dressart3d.com for details.

3d-Modelling-the-Sleepy-Hollow-Hessian-Sword-@ dressart3d.com

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