Introduction: Zombie Weapon

This Instructable will demonstrate the process of How to Build a Zombie Weapon. I have taken quite the fine furniture approach by using some exotic scrap woods while avoiding using a rusty saw blades. Therefore the whole piece contains only wood held together by glue. This would be a nice project to be put together using only joinery. (I therefore open the challenge to anyone willing to try.)

Here is the material list to complete this project:

- Ash Wood Approximately 27 x 8 x 1 inches for the base of the bate

- Strips Purpleheart and Purduk approximately 48 x1/2 x 1/2 for the spikes

- Two strips of Purpleheart 10 x 1 x 1/4 - For handle

- One block of Purduk 2 1/2 x 2 1/2 x 1 for a top cap on the bat.

- Wood glue

- CA glue

- Two part five minute epoxy

- Paste wax or any type of finishing


- Table saw

- Hand saw

- Belt Sander

- Sandpaper

- Mortiser

- Clamps

- Miter Saw

- Mallet

- Large bar clamp

- Vise (optional)

Step 1: Instructional Video

If you are interested please check out my build video. I feel that between this Instructable and my YouTube video anyone would be able to understand the process to create one on their own. Also, the video is part of a challenge collaboration started by the YouTuber Mike Fulton. This collaboration was inspired by the TV show The Walking Dead. My effort is only 1/25 the overall collaboration so there are 24 other similar project videos.

Step 2: Gather Scrap Wood

In my shop, I have quite the collection of scrap wood. I found a nice piece of Ash approximately 27 x 8 x 1 and a few pieces of Purpleheart and Purduk 3/4 x 3/4.

Step 3: Cutting Scrapwood Down to Size

For this step, I use a table saw to cut the Ash Wood into strips approximately 27 x 2 1/2 x 1 and the thin strips of Purpleheart and Purduk are squared up to 48 x 1/2 x 1/2.

Step 4: Cutting and Glueing Ash Wood

These few steps will be to build the base of the bat.

First, I cut two of the three ash strips approximately 27 x 2 1/2 x 1 long down to 12 inches lengths.

Second, I glue the sides of remaining long pieces and place the short pieces to one end and clamp until the glue sets.

Step 5: Saw to Square

At this point, I saw my base to square lengthwise while removing the excessive glue away.

Also, on the table saw, I cut a 45 degree angle to create a bat-type shape. (Not pictured)

Step 6: Mortisering Out Spike Holes

In this step, I use my mortiser to drill/chisel out 1/2 x 1/2 square holes for tenon spikes. I found that the process was a lot easier if, I drilled out the hole first on my drill press. (The drilling process not pictured)

Cheaper solution - For a similar type of construction, a builder could exchange square pegs for round dowels. This would really be a wise decision since both dowels and drill presses are cheaper/easier to buy.

Step 7: Optional Step - Decorating Handle

In this step, I found some extra scrap of Purpleheart to decorate the handle. By gluing and clamping the piece of Purpleheart approximately 10 x 1 x 1/4 on the long piece of Ash wood to fashion a handle.

Step 8: Handle - Cutting to Shape

This step is where the handle is cut into shape. I used a general ripping hand saw to make the long cut and a pricey Japanese dovetail saw to make the difficult angle cut.

Step 9: Bat Head Cap

In this step, I make the head cap part by cutting a piece of Purduk to the size of 2 1/2 x 2 1/2 x 1 inch. To secure the head cap; I use two part epoxy with a large bar clamp.

Step 10: Shaping Bat Head Cap

This step is about shaping the Bat Head Cap. I use my 1x30 belt sander to create the shape that I desire. The first step is to knock off the edges of Purduk to match the shape of the bat. The second step is rounding out the top-most of the bat. What I wanted was a round shape at the tip, and to make the round section flow into the octagon shape of the bat. Simply, I sanded only the Purduk and avoided the Ash wood completely.

Side note: This turned out to be the best looking part of the project especially since I sanded down the project to a 2,000 grit sand paper finish.

Step 11: Quick Tip - Cleaning Sand Paper

This picture is where I am using a block of rubber to clean the sanding belt. This is not quite essential to the project but is a good tip on getting the most out of your consumables.

Step 12: Sanding

Sanding - I know is everyone's favorite activity. I started with pure elbow grease but, I later moved on to using an electrical sander clamped into a vise. This trick/hack; I highly recommend it because it will save a lot of time and effort.

Step 13: Part 1 - Cutting and Shaping Spikes

Again, I use my vise to clamp the long strips of Purduk and Purpleheart so they can be easily cut down to size - approximately 1 1/4 x 1/2 x 1/2 inches. After all of the pieces are cut; I use my 1x30 belt sander to shape the spikes in two different ways. First, I shape one side to easily enter the mortise and it should remain square. Second, I shape the tip of the spike so it is round.

Step 14: Part 2 Shaping Spikes

After attempting to place a spike into a mortise I had noticed that my 1/2 x 1/2 Purduk and Purpleheart spike blanks were over-sized by just a touch. To resolve this issue, I taped some 220 grit sand paper to my bench. To find the correct amount of wood removal; I went slowly counting my strokes. My first run was 3 strokes on each side of the spike blank. In the end, I had to stoke the spike blanks on all four sides ten times for the blanks to fit the mortise. I may have gotten away without doing this task, but I felt that it was worth the effort. With adding 8 spikes into a grain line that runs up the bat there was a chance that the wood may have split.

Step 15: Glue and Placing Spikes

In this step, I use CA glue to secure the spikes into place. A liberal amount of CA glue was dabbed on the square end of the spike. I used a mallet to tap the spikes into place and sprayed the CA activator to cure the glue.

Step 16: Finishing

A paste wax type of finishing was used because it is easy to apply on this difficult piece and there is hardly any drying time.

Halloween Costume Contest 2016

Participated in the
Halloween Costume Contest 2016