Advice for Making a NON-Belegarth Legal Cosplay Weapon

[Cheeseheart]

Howdy guys. Someone in the SoCal area is doing some sort of Cosplay thingamajig and wants me to build something that approximates the weapon that goes along with the costume. I have a few ideas, but I'd love to hear some suggestions for how to go about making this thing from people who have more experience doing special projects.

Some questions I have are:
-should I even use a core?
-what types of foam are best for these kinds of projects? Will standard blue foam do the trick, or should I attempt to find something more rigid?
-Will spray paint destroy foam (as I am not really familiar with the plasti-dipping process)?

My assumptions are that the girl wants it to be pretty, as close to the actual thing as possible, and does not intend to use it for ANY kind of combat.

[bo1]

i would recomend using some .5 fiber glass, grind the center half way though on both, then gorilla glue them together. then blade in a manner you like, i would do all 4lbs eva and use a stanley sure form to shape them, then plastidip for color and finish.

[Forkbeard]

You could also get some 1/4" or 3/8" abs plastic to use as the core. Cut it to that cross shape but maller and foam it up to size. Bevel the edges with some kind of guide like Bo says.
Join the plastidip artist group on face book for full PD instructions, they will love to help you with this.
Shouldn't be too hard to make just like the picture.
FB

[Tobia Blackthorn]

From experience: Spray painted blue foam simply looks like spray painted blue foam. Its not smooth enough for a decent look.

[randy]

for the core I would use 2.2# plank. cut out the basic shape with that, then add MC or blue camp pad to the striking edges and to cover the plank. then use a sander to create the edges. Finally plasi dip and paint.

Most likely wouldnt stand up to bel/dag but normal tap cosplay stuff, should be fine.

And you dont need to cover yourself by saying its not for you...

[Fitz Caliston]

If they don't intend to do any combat with it, but just want it to look cool I'd build the main piece (core) using the heavy floor mat foam then skin that in MC/craft foam, build up the blades using MC again and shape it. Then PD it, paint, seal and done.

As Fork mentions the FB PD group should be able to answer any of your questions.

[Cheeseheart]

Thanks for all your advice folks. Randy, you caught me, the Cosplay costume and weapon are intended for me

I like the floormat idea, at this time, it is the most feasible method for me to use. I've been intending on getting some EVA foam, and so I may go ahead and do that if it can arrive in time, as the thing needs to be done in a few weeks. I'll look into the plastidipping, but I make no guarantees that I'll even know which questions to ask. I felt that spray paint wouldn't properly do the trick, anyway. Just a thought, why did no one suggest PVC as a core, connected by a four-way joint? It would be cheap and easy, and if the thing wouldn't be used for combat, the weaknesses of PVC wouldn't have to be considered.

[Fitz Caliston]

Personally I wouldn't use pvc as it would be much bulkier then the picture.

If I was going to make it for melee combat I would us fiberclass slats that they use for the fabric road signs in construction zones.

Read through my PD shield tutorial at www.calistonarmory.com and Wynar Weapon PD tutorial on the Dag boards and you should have all the answers about PD you need. If your comfortable with a spraypaint can you can PD, and it'll come out looking much better an be longer lasting.

[Arrakis]

Here's a resource. Ask her:

http://fevereon.deviantart.com/