Like any good Viking or Dwarf; if you have a big shield, you need a big axe. So, here's part 2 of our little mayhem making.

For this, we'll make a double bit axe modeled somewhat after Gimli's axe from Lord of the Rings. Why? It's good, solid and heavy.

The tricky part was making a heavy axe while balancing it with sufficient padding to not cause someone damage. With this, you'll feel the hit, but it will be something like getting hit by a Jotun's memory foam mattress rather than a heavy hammer.

You will need:
A haft (PVC with poplar dowel core left over from a previous endeavor)
A core (1/2" rubber sheet)
Padding (more neoprene-like foam)
Fasteners (Hockey Skate lace, bolts and contact cement)

Step 1: Cutting the Core

The core is what will give the axe's bit its shape. Thick rubber is a good way to maintain flexibility and shape, especially if you fold it in such a way that it helps add strength. For this, I took a 14"x14" sheet of 1/2" rubber and cut out sections to allow for folding over the haft.

For this I used a band saw after having tried an Xacto knife and a box cutter, neither of which gave great results. So, I took a fine-tooth band saw blade and slowly cut my way through it, ending with the shape below.

I then drilled a hole through rubber, and a corresponding hole through the center of the haft (not quite center, since cylinders are difficult to drill through and attached it with a pretty decent bolt and washers.
Any metal in a boffer seems like a bad idea. I would recommend punching two smaller holes in your core side by side and use a zip tie to secure the two halves. Who knows, you may have tried that in the past though and it didn't hold up well. <br> <br>I, for one, would like to see more boffer instructables. They can be a lot of fun and I'm glad people are putting them out there!
If I had teflon or nylon bolts, I would've used those. However, I tested them out on myself first at full swing and you can't even feel the metal through all the padding. <br> <br>I have tried the zip ties before, and I've only found a way to make them work well for adding hilts and stuff around hilts. Having them go through the foam always makes the foam tear really quickly for me. <br> <br>I keep adding them under Nerf and suggesting Boffer as a subcategory for something. <br> <br>Best of luck!

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Bio: Hi, we're Dara and Nash. Industrial designers, tinkers, and mayhem builders. Follow our travels.
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