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They generally made multiples- real bona-fide weapons ("hero weapons") for closeups, and lighter, safer copies made of aluminum or rubber for fights and action scenes. I understand they went through a *lot* of aluminum swords! Also, apparently, they had to keep talking Viggo out of using his Hero Sword in fights, lest he injure somebody.
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The entire plot of The Lord of the Rings could be said to turn on what Sauron didn’t know, and when he didn’t know it.
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