hand axeI have been building a few different variations. I started with the design linked (specifically the hand axe. Only on a longer pole ofcourse.
I really like using plank foam shield scraps. They have the right amount of strength to weight ratio. I used DAP (ofcourse) to attach the core to the foam. then used plastic box tape to torque wrap the foam to the handle (think lashing pieces of wood together) During this, I took a thin piece of leather and connected/lined the inside curve of the foam to the core. Again lots of torque wrapping.
For the striking edge, I used layers of yoga mat. I tried camp pad and didn't think it would pass a hit test. The yoga mat is just soft enough that you get a big thump from the weapon without the pain associated with a larger weapon.
For cloth cover, I tried several different things. Finally deciding that 2 layers of womens trouser socks was easiest and looked better than grip tape. If your patient, you can make a cover out of cloth, but for a gimmick weapon im not that invested in making a cover.
Pictures: