Icons Xena Chakram Prototype

This is the Xena Chakram licensed prototype by Icons (1997), early version also used by Timeless Collectibles in 2000. Unique solid cast metal. 1 of a kind.

The best selling Universal Studios licensed, authorized and authenticated Xena : Warrior Princess Chakram prop replica weapon was an amazing feat of reverse engineering at Icons Authentic Replicas.

When Icons licensed the Xena Chakram from Universal Studios in late 1996 early 1997, it proved to be a complex prop replica to accurately reproduce. 1st : there was the hoop shape, 2nd : the beveled edges, 3rd : the engraving pattern (which varied on both sides), then there was the gold-colored painting on the interior section of the circular hoop, then there was the recessed areas for Abalone shell accents. All of this proved to be quite a challenge. And Icons R&D literally pulled their hair out attempting to reproduce a prop replica thousands of times that was only designed to be reproduced a few times for use during production by actress Lucy Lawless.

The Icons Xena Chakram project was supervised by Tim Huchthausen at Icons Fabrication & Design Group, which was staffed by Film and Television, professional prop-makers and SPFX miniature builders. Tim was the senior prototype engineer of the Icons FDG in 1998. He also is respected for his gorgeous work with Bronze Artist Jody Samson and production designer Ron Cobb on all the Swords seen in the feature film Conan the Barbarian.

This rare Icons Xena Chakram replica, was the first product prototype fabricated by Icons Authentic Replicas for presentation and discussions for product approval with Universal Studios in Southern California. It was cast in solid white metal at an outsourced metal casting company and then engraved, and the Abalone shell accent recesses placed. This version was then polished, stenciled with a computer rendered pattern that replicated the screen-used original and then hand painted. The Abalone shells, found at a San Pedro, California sea shell shop were then added. The custom rock-like base was hand sculpted at Icons Fabrication and Design Group, molded, a 1630 casting created and then a second mold created which yielded many custom rock-like bases. These were custom airbrushed to appear like stone and then the recessed Chakram holding area lined in black velvet as well as the rock display's base.

Upon much examination, discussion, polite debates, heated arguments and knock-down drag-out-fights amongst Icons staff, it was decided to abandon the solid metal cast version of the Chakram and instead go with an all aluminum polished version, which proved to be much more elegant in design, lighter in weight, easier to manufacture and control quality. Icons would purchase 30 foot long aluminum tubes and an outsourced professional machine shop, who specialized in aerospace and aviation components, would literally dice these aluminum tubes into the shapes of Chakrams.

The Chakram's stencil decal was very difficult to engineer, apply and utilize during painting, as it was very graphically complex and if it was not applied correctly or pulled off too quickly & not carefully enough, it would strip the gold color paint trim. Icons had to utilize a special metal powder paint to prevent non-adherance of the paint and assure quality in consistency and durability.

Luckily, the cylindrical Xena Chakram Abalone stones proved in the end to be a standard size often used by jewelers in many parts of the world. But Icons only discovered this fact after it had researched and purchased a custom-made wet sander used to cut sea shells for thousands of dollars.

This rare Xena Chakram prototype weighs much more than the final production samples manufactured by Icons. It feels like an actual weapon. Its line work and sheen are much more primitive than the Universal Studios Chakram replicas that were ultimately approved and shipped to customers. Though it was originally intended that the Chakrams would be a large edition, less than 1,000 were ever shipped worldwide by Icons. The Chakram proved to be one of the fastest selling Icons products of all time.

This piece was often handled during meetings referring to it as the final design specifications for the new version were being discussed at meetings at Icons. Therefore, it is not in perfect condition.

That prototype includes some additional unique items relating to the Icons Chakram : a standard issue Xena cloisonné plaque with Icons and the Universal Studios logo and a very unusual item, an uncut sheet of two official Icons Xena certificates of authenticity, that are unnumbered and unissued which also feature the Icons official logo, the Universal Studios official logo and Director / Producer Sam Raimi's production company's official logo.

This particular Xena Chakram was also utilized by the successor company to Icons Authentic Replicas, Timeless Collectibles. As many Icons replica collectors know, in the Spring of 2000, just weeks prior to Icons closing its doors forever, a group of investors attempted to create a new licensed replica company that would carry on the quality work and tradition of Icons. So, this specific prototype can also bear a rare paper plaque featuring the Timeless Collectibles logo.