I wanted a different set of weapons for my costume and I decided to take a melee approach and build a Storm Shield and Power Maul. I've posted the shield already so now it's time for the maul.
I'm my own worst critic so I'm not 100% happy with the turnout but for my first try, I shouldn't complain.
It started with a 4ft dowel, 1&1/4 inch thick. I glued 2 mats together to get the thickness I wanted. My suit is a 935 so it had to be a big weapon. And it's 40k... Everything is over the top!
I went through a few paper designs until I came up with this one. I didn't want sharp and pointy so I stuck with traditional designs.
Once the glue was set I traced the shape on the foam and started cutting. I was blessed with a scroll saw from my brother-in-law and it made cutting a breeze. Using a high TPI blade made short work of the foam and kept a clean edge. Not as clean as an Olfa knife, but damn near. Once they were cut, I sectioned off the dowel and hot glued the sections on. I was going to use 4 but I liked the look of 6; and using 6 filled the whole space. Originally the paint was bright aluminium but it looked odd so I changed it to a dark grey. I won't go through the amount of paint scheme changes but there were many. I had attempted the burning embers style by Emily but there wasn't enough space on the edge for it, so I settled for some red/yellow/white drybrushing.
The middle part of the dowel was painted in a metallic gold for no reason other than to have it stand out. The grip was done with strips of craft foam and painted a combination of black and brown. I kept it extra long so I could use it two-handed, and I didn't want to cut it too short and end up looking funny. The little studs are push pins from the Dollarama.
When it was done, I felt there was something missing, so I googled again and decided to add some futuristic bits. I made a half cylinder and glued it to the side with some hoses coming out and into the maul head.
It's not as heavy as I expected but I'm thinking I'll be sore after carrying it around for hours.