My aim was to produce a near full-scale replica of the Halo 3 gravity hammer using materials and tools commonly found in households, or those easily available to buy locally. Some metalwork skill is useful for undertaking a project like this, and it helps if you're already familiar with Pepakura (See step 1), but this is a fairly easy concept to get the hang of.
Materials are as follows:
34 Sheets of 160gsm A4 card (Some call it cardstock)
150cm x 3cm Aluminium or PVC tubing
Several metres of Steel or Aluminium tubing (1-1.5cm diameter, square or round)
500ml can of expanding insulation foam (May require more if it is a low expansion variety)
Fibreglass and resin (Optional)
5mm Thick modelling foam for the head details
Spray / Acrylic paints (Greys, silvers, blue, black, white)
Fabric / Leather swatches for the handle grips
Step 1: Papercraft
The main shape of the hammer is created from a paper modelling tecnique known as "Pepakura". It's more commonly used for armour or masks, and strengthened with fibreglass, but it is also fairly effective for making weapon props. The program called "Pepakura Viewer" allows specially made 2D nets to be printed (Just use google to find the files, or search for them on 405th.com)
There's no point in me providing a step by step guide to Pepakura, as there are already so many guides, but the basic idea is print, cut out, and stick together. I prefer superglue as a method of sticking tabs, because it sets faster than hot glue, and has a negligible separation between the layers of card/paper.
The model I used was composed from about 6 main pieces, all intersecting on the virtual model, So I had to decide which I would create my own cuts/tabs for (All of the head, some bits on the shaft, and the hilt), and which I would make exactly as the net dictated, and cut to fit the main model after (Two blocks between the head and the blade). The blade itself only needed some holes cutting to fit the steel tubing through.