Flanged Mace

My last melee weapon, Tiff's Axe, was designed with a specific character in mind. This weapon, however, is a completely random design. I wanted to try out a new technique for making blades out of EVA foam, here's how it turned out.

Materials

• EVA foam floor mats
• 2mm thick EVA foam
• 3mm MDF
• Contact cement
• Hot glue
• PVC glue
• 32 mm diameter thick walled PVC pipe
• PVC coupler for pipe
• Foam primer (book binding glue + acrylic gesso)
• Acrylic paints
• Oil paint
• Matte varnish

The design
Okay, so what's this new technique I mentioned? First of all, the design of the weapon. I did a lot of sketching and came up with a hexagonal central shaft, and six blades arranged around it to form the mace head. It's the blades I wanted to try something new with.
If you want to make a blade out of foam, you need to sandwich a few layers together, and if you use floor mats, this means you'll have to remove the texture from one side. This is a tedious and very messy process. Even with a shop vacuum hooked up to my bench sander, it still makes a lot of dust.
Except very small blades (such as daggers), you usually need some sort of core to add some support, or else you end up with a floppy blade. For Tiff's Axe, this wasn't necessary because it consisted of four layers of foam, but my first Battle Axe has an MDF core. This gave me an idea.
Instead of sanding away the texture, I wanted to try glueing it with the textured side to an MDF core. For the blade edge, instead of sanding away foam, I made some beveled cuts and used strips of foam to create the edge. A band saw is a must have for this!
I did some sketching and doodling before I got started. I almost never let anyone look in my sketchbook, because there's so much ridiculous, stupid crap in it, but for this once, I'm giving you a peak inside. The notes are in Dutch, so there's a good chance you won't understand it.

My first attempt was polyurethane wood glue. This stuff expands a bit as it cures, and I hoped it would fill up the texture of the floor mats. Too bad, it didn't work out, the glue hardly binds to the foam. I tried a hot glue gun instead, this worked much better. It only needs to be glued down in a few places to keep the core in place.

The blades
For the blades, I made six MDF cores. They have the same shape as the blades themselves, but I also made a tenon on the side that will be attached to the central shaft. In the shaft, I'll cut a groove so it will form a strong connection.

For each blade, I cut two large pieces of foam, wich were glued to the MDF core, and strips for the edges. This requires some care with the angles of the cuts to make it all fit nicely together. Like I said, a bandsaw with a mitre gauge is a must have for this.

Turned out quite ok! I rounded the tips a bit with my Dremel, because otherwise they would get damaged too easily. The result is a light, rigid blade with a cutting edge without any sanding!

The central shaft
The central shaft consists of six strips of foam, glued together around a piece of PVC pipe to form a hexagon. On one end, I glued a PVC coupler to the pipe, for attaching it to the handle.

The ends of the shaft are made by sandwiching a few layers of foam, cutting into shape, and in the case of the lower end, cutting a hole for the handle.

Next, I cut slots in the handle for attaching the blades, a bit like a tenon-and-mortise joint in woodworking. The blades were glued on with more contact cement.

And finally, some decorations with thin, colourful craft foam!

The handle

For the handle, I used a piece of thick walled, 32 mm white PVC pipe. These come in several wall thicknesses, mine is 3 mm thick. I wanted to make it look like wood (part of it), for that I used a very simple technique. All it takes is sandpaper, a wood rasp and oil paint. The pipe has to be white for this to work!
First, I sanded the entire pipe with #80 grit sandpaper, and then I used a wood rasp to carve a wood grain into it. Just some random, deep scratches. After that, I sanded again with #80 grit sandpaper, and then worked my way up to #400 grit.

To achieve the wood color, I put some dark brown oil paint on a sponge and rubbed it on. I used this technique before, but with acrylic paint. The downside of acrylic is that it dries too fast for this. You have to spread the paint really thin, and acrylic almost dries instantly when you do that. Oil paint stays wet much longer, so you have plenty of time to get it right.

It took about three days for the paint to fully dry. After that, I made some foam decorations on the handle. One half of the handle will be wood, the lower part (where you hold it) will be wrapped in leather. But first, painting!

Painting and finishing

The paintjob started, as usual, with my foam primer, a mixture of acrylic gesso and book binding glue. I added a bit of black to the mixture to get a grey base coat. The mace head and foam decorations on the handle were treated with this.

As for the painting itself, I didn't take much pictures of that. Most of it was done at a local arts faire, and I already had more than enough stuff to drag along, I didn't want to bring a big heavy camera. I did take a picture with my phone, so forgive me the crappy quality.

So, basically, here's how it went. After the primer, I sprayed on a gray base color with a spraycan. Next, a black wash (that's what's going on on the picture above), followed by white drybrushing. The drybrushing made all the edges and ridges really pop. It already looked like metal without any metallic paint!

I sealed this with matte spray varnish, and then drybrushed a very thin coat of silver. I put the metallic paint on top of the clearcoat, because with my battle axe and 12-sided mace, the clearcoat kind of ruined the metallic effect. Here's how it turned out:

For the handle, I cut a 5 cm wide strip of vinyl leather, put on contact cement and folded about 5 mm on one side, to hide the edge where I cut it. It then got wrapped around the lower part of the handle, the final bit got glued on with super glue. All that was left then was put the head and the handle together!

It turned out quite good, but my wife had a few ideas for improvement. First of all, the wood color is too bright, next time I should use a more grayish color. Second, the weapon looks too new and unused. It should have some cracks and dents in it, so it looks like it has seen some action. I'll keep it in mind for next time!



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Hammerfall Sketchbook

Here's another post about a sketchbook I made! I don't do posts about every book anymore, since it's more or less always the same, but this one is a bit special.

One of my favourite bands is Hammerfall. In the music video of their song "Hearts on Fire", a skeleton arm holding a book pops up at around 15 seconds into the video. This book has been on my to do list for a while, so here it goes!

Materials 

• Daler-Rowney A4 sized sketchbook
• Carboard
• 3 mm MDF
• PVC foam plate
• Kraft paper
• 180 grit sandpaper
• Acrylic paints
• Book binding glue
• Super glue
• Gilding wax
• Matte spray varnish
• Red felt 
• Leather straps

Gilding the paper edges
In the past, I have tried achieving a gilded paper effect using acrylic paints. It didn't work very well, because it more or less glues the edges together. This time I tried something different: gilding wax. It took me a few attempts to find the right method, but here's how it's done.

The most important thing is to work in thin layers. Thick layers will flake off easily. I clamped the book together and brushed on a thin layer of wax. Next, I took away the clamps and flipped through the book, to make sure no pages stick together, and let it dry for 24 hours. This is repeated until the desired coverage is achieved (about 3 layers). After the final layer has dried, the book is clamped again, and the gilded edge is buffed with a cloth. 

The logo
The Hammerfall logo (an H and an F combined) is made from cardboard, PVC foam and 180 grit sandpaper. I first cut out the letters using a hand saw, and then rounded the edges with a knife, files and sandpaper. The disc is made from cardboard and sandpaper for the texture, and the edge around it is also PVC foam.

 
The painting started with a few coats of primer, followed by base colors. The inside is burnt umber, the outside and the letters are raw sienna. To add some variation, washes of black were applied to the inside, and burnt umber for the letters and edge.

Next, metallic bronze was used for the entire logo. A thin coat, so the underlying color shows through. The letters and egdes were lightened by an additional drybrushing with gold, and the inside was darkened with a black wash.

The book cover
I studied the video carefully to get a good picture of the book cover. The video is quite low quality, and the book only briefly shows up, once at the beginning, and then again at the end.
The cover is pretty simple. A panel with the logo recessed in it, a beveled edge all around it, and two leather straps that wrap around the spine. Shouldn't be too difficult!
The panels are made from cardboard, and the edge from MDF strips. The inside of the edge has a 45° bevel. Since I finally own a bandsaw, this was easy to make! I cut some MDF strips with a 45° bevel on one side, and made a frame around the cardboard panel.

In the front panel, a hole for the logo was cut, and both the front and back panel had slots for the leather straps cut. Next, the panels were glued to the book and the entire book was covered with wrinkled kraft paper.

Painting was done the same way as my previous books. Black followed by a mixture of burnt umber with a bit of red, next a thin coat of raw sienna and finally a metallic copper drybrushing and a matte clearcoat. I have been experimenting a bit with different color combinations, and I hope to finally start making something else than the standard brown leather color.

Finishing
To finish the book, I cut two straps from the pile of scrap leather I have lying around and glued them in place with super glue. The logo was glued in place, and the inside of the covers was finished with a piece of red felt.

And here's the final result!

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Zombicide Machine Guns, part 1

Here's the second part of my Zombicide project! In the first part, I made a guitar axe. This time, I'm going to make the machine guns, one full sized Uzi-type gun and two identical mini-sized guns.

This is also my second attempt at making a video tutorial. The first one failed quite miserably. I'm not good at talking in front of a camera, and I forgot to take pictures besides video. Also, this will be a two part tutorial. The first part will deal with building the guns, the second part will be about painting them.

Materials and tools

• EVA foam floor mats (10 mm)
• 2 mm EVA foam
• PVC pipes, 20 mm and 35 mm diameter
• PVC foam plates, 2 mm and 5 mm
• MDF scraps, 10 mm and 3 mm
• Neodymium disc magnets
• Contact cement
• Super glue
• Wood glue
• Construction adhesive
• Hobby knife
• Rotary tool with flex shaft
• Belt/disc sander
• Heat gun
• Glue gun
• Band saw

The video
I recorded more or less the entire build on video, and this time I didn't screw up! Again, I shot waaaay more footage than I actually needed.
I removed the original audio and did a voice over. I'm not really good at talking in front of a camera. Apparently, my placeholder word for when I can't come up with the right word is "falafel". For example, "Next, I'm gonna drill two holes and glue in the... the... falafels with super glue." I used my phone as a voice recorder. It did a decent job, but I should invest in a decent microphone nonetheless.

Design
Before I could start building guns, I had to design something first. The easiest method would be using pictures of real guns and try to replicate them, but that would be a bad idea. I would end up with props that look way too realistic, even if I didn't replicate them perfectly. Conventions have quite strict weapon policies these days, and realistic looking weapons aren't allowed most of the time.
So I decided to design my own guns from scratch. I did use pictures of real weapons as a reference, mostly for getting the proportions right. I imported them into Inkscape and started drawing. I used an full size Uzi and a Micro Uzi as a reference, starting with the mini weapons. The most iconic part of the guns I was trying to mimic are the magazine in the grip, and the sights, so I made sure to include these. The magazine has an opening in the sides, showing the ammo inside.
Another feature I added was a muzzle brake. This is a sort of barrel extension with holes in it, and its purpose is to lighten the recoil of a gun. It's hardly ever found on this type of weapon, but it looks cool. I also wanted to make the magazine removable, both for ease of storage and transport, and for coolness.
After I was finished with the small gun, I used it as a base for the full size gun. I kept the grip, but enlarged the body and gave it a forward grip. Both guns also have an accessory rail on top, so in the future I can add stuff like high tech sights or other gadgets.
If you're interested in these designs, you can download them here for free. They are made using Inkscape, an excellent free cross-platform drawing program. The drawings are A0 and A1 size, so for printing you'll have to chop them up a bit. I had to cut them into A3 sized pieces for printing. I'm giving my designs away under the Creative Commons license, so if you use them, be a nice dude and give me some credit!

Full size machine gun, SVG file, 268 kb
Mini machine gun, SVG file,  242 kb

Getting started
I had ordered a band saw for this project, a tool I had been planning to buy for quite a while. Unfortunately, a few days after my order, I received an email from the store it would take a bit longer for the saw to arrive. The guns themselves kind of required a band saw, so in the meantime I got started on some of the small parts.
For the magazines, I didn't need the saw. They are made out of 10 mm EVA foam, sandwiched between a few layers of thick cardboard for stiffness and 2 mm foam. The bullets are made from a wooden dowel, painted with wood primer and brass spray paint. The sides got sanded flush on the disc sander, and an extra layer of foam was wrapped around the bottom of the magazine.
I wanted to make the magazines removable. To keep them in place when inserted into the gun, I put two small neodymium magnets in each magazine. I drilled two holes in the top, glued the magnets in place with super glue and then glue another layer of thin foam over it.

The sights and accessory rails are made out of 2mm thick rigid PVC foam. This material is easily softened with a heat gun and bent into shape; the different parts are glued together with super glue. For the adjustment screws on the sides, I simply cut the heads from a few screws using my Dremel and a grinding wheel, and glued them on with super glue.
The barrel consists of two pieces of PVC pipe. The barrel itself is a 20mm pipe, and the muzzle brake is a 35mm pipe. For the slots in the muzzle brake, I drilled a row of holes, cut the remaining plastic between the holes away with my Dremel and cleaned it up with a file. Another thing to add to my shopping list: a drill stand, because drilling a row of holes accurately isn't easy freehanded.
To fit the 20mm pipe into the 35mm pipe, I wrapped two layers of thin foam around it. This almost fit, but I still had a little bit of space left, so I wrapped some electrical tape around the foam until it fit firmly. The transition between the two pipes was then sculpted with Apoxie Clay. This is a two component sculpting medium that hardens into a rock solid mass that can easily be sanded, without shrinking or cracking.
A few discs made out of PVC foam, some more Apoxie and a few strips of thin EVA foam finished the muzzle brake. I did paint the interior black before I finished it, because it would be too difficult to paint it afterwards.

I wasn't really pleased with the barrels. The muzzle brake looked crappy, so I decided to start over. I used two pieces of PVC pipe again, but the other parts were 3D printed. Since I don't own a 3D printer, I headed to the makerspace at the Hasselt university and printed it there. The parts were modeled in Blender, an incredibly powerful free application, but with a steep learning curve!
The next day, a friend of me who runs a computer store told me he had a printer set up in his store for demos, and if I wanted something printed, I just had to send him the STL-file. I needed one more printed part for the barrel, and that's the part that connects the barrel to the gun itself.

The gun body
When my new band saw had finally arrived, I could get started on the gun body! I had already cut out the shapes I needed from my foam mats and sanded away the texture. For each gun, I needed 5 pieces of foam; the body is about 5 cm wide. With all the sanding, however, the foam was a bit less than 1 cm thick, so I used some 2 mm foam to bring it to the right width.

The handle needed a hole for the magazine. I glue three layers of foam together and then cut out the hole. Next, I drilled holes for the magnets (to keep the magazine in place), glued them in place and, after checking if everything fit, glued on the last two layers of foam.
Next, I cut the foam blocks into the right shape on the bandsaw. The upper part of the gun was easy, since these were all straight lines. The cuts were cleaned up a bit on the disc sander; special bandsaw blades exist for soft materials that produce a very clean cut, I should try to find one of those. The grip needed a bit more work, this was done with my Dremel and a sanding drum. I had to be very careful here not to sand away too much!

The raised details are all made out of 2mm EVA foam, cut with a hobby knife and glued into place with contact cement. The details on the handle were made by making a shallow cut and then heating it with a heat gun, causing the cut to open, and with a chainsaw sharpening bit in my Dremel.

Finishing touches
The trigger and trigger guard are made out of MDF scraps. Whenever I use MDF, I keep all the little scraps (well, not the tiny ones of course, anything bigger than the size of a playing card), they always come in handy for stuff like this. I used 10 mm and 3 mm thick MDF, wood glue and lots of cutting and sanding.
To install the trigger, I cut out a slot in the foam gun body and nudged it into place. I couldn't use contact cement for this, so I used a bit of construction adhesive. This has the added advantage to fill up any voids, so it bonds well even on a rough surface.

For the barrel, I carefully drilled a hole in the gun body. Since I don't have a 20mm drill bit, I enlarged it with my Dremel, until the barrel fit. Again, a bit of construction adhesive, and some hot glue. I was all out of super glue at this point, that's why I used the hot glue.

And then, some final finishing touches. I put the sights and accessory rails in place, drilled some small holes and put in some screws. The two last parts were the loading grip and the fire selector. The loading grip was also 3D printed, the fire selector is made out of MDF.

Coming up...
The next part will all be about painting and weathering the guns. They look quite silly and colorfull at the moment, but that's because I used craft foam sheets in all sorts of colors. Don't worry, the finished guns will look badass gunmetal grey with chipped paint, scratched metal and dirt!

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