What you will need:
* color printer
* photo editor
* scrap cardboard
* liquid nails, wood glue, or some other construction adhesive
* 3M spray adhesive
Step 1: Print Your Pickax
Open the picture in Photoshop, or your editor of choice, and scale the pickax to the size that you want. Ours was about 22" high and 16" wide. Save this file as a .pdf. The file can then be opened in Adobe and printed to a color printer. The trick is to print it with no scaling (100% size). To do this, select: Page Scaling>Tile Large Pages. You will have to trim the pages and tape image together. Print two copies - one for each side.
I had access to a color laser printer that had an 11x17 feeder. This made for less cutting and taping, but 8.5x11 page size would work fine too.
Leave a larger border of white around you image. This will be more accurately trimmed off in a later step.
Step 2: Cut and Glue Cardboard
Step 3: Cut the Final Shape
When your adhesive is dry, the shape can be cut into the cardboard. I used a utility knife. It was tough to cut all of these edges through four layers of cardboard, but it only took about 15 minutes. A jig saw or band saw would have made quick work of this step.
Step 4: Tape and Paint the Edges
Step 5: Gluing the Printed Image to the Pickaxe
The paper will inevitably get some tears or wrinkles during this process. Once these are pressed flat, they are hardly noticeable.
The pickaxe is surprisingly durable and just plain fun to wield!