Ok this is the first cast of the blade out of the new mould. I added the cross guard so you can see the overall look. It is almost there but the foam is a little heavy at the second. I think it is the age of the foam as it has a 6 month shelf life and I have had this kit for 6 years. I am building a heat box to warm up the moulds and the foam. I hope that will help. The blade is 400 grams and I want to get it down to 300. To be fair I am most likely being overly worried, but I dont want anyone getting knocked out by a weapon that is to heavy.