You can craft an intricately detailed mace to enhance many different costumes. This mace is simple to construct, inexpensive to build, and impressively detailed
- 12 mm EVA foam
- 2 mm Craft Foam (from Walmart)
- Hot glue
- 36" of 3/4" Rigid PVC Conduit
- Computer with printer
- Band saw
- Contact Cement
- Hair dryer
- Wood file
- Utility knife
- Permanent marker
- 220-grit sandpaper
- Spray paint-black
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Step 1: Print and Cut Template
Using Photo 1, create a template for the mace blades and triangles.
Trace blades and triangles of template onto 12mm EVA foam. Cut out 6 pieces of each (blades and triangles) with band saw. Using a wood file, remove any texture from the backs of the pieces.
Glue together two small pieces of EVA foam. Draw a triangle 1" x 1-1/2" x 1-1/2" onto the foam. Cut it out with band saw. With a hair dryer, heat up all seven triangles to remove any air bubbles.
Step 2: Add Detail to the Blades
Using a utility knife, etch designs on each blade according to the photos. Next, using a hair dryer heat up the six blades
Step 3: Glue Blades and Triangles Onto PVC
Using 220-grit sandpaper, sand PVC pipe to roughen surface, allowing glue to adhere more easily.
Using a protractor, make six marks at 60 degree intervals on one end of PVC pipe.
Using contact cement, adhere custom-cut triangle to same (top) end of PVC pipe.
Using contact cement, adhere blades at 60 degree intervals, according to photo.
Adhere six small triangles below each blade as shown.
Reinforce all seams with hot glue.
Step 4: Cover Glue Seams With Craft Foam
Out of 2mm craft foam, cut six diamond-shaped pieces, approximately 7-1/2" x 1-3/4"
Hot glue each diamond over glue seams between blades as shown
Step 5: Handle Trim
Out of craft foam, cut a 1" wide strip long enough to wrap around handle. Glue it in place with hot glue just below triangular spikes.
Cut 6 strips from craft foam 7" x 1/2." Glue them in place below 1" strip to form hexagonal cover over the handle.
From EVA foam, cut six 3/4" squares. Cut off corners at 45 degrees as shown, using a band saw or utility knife.
Adhere them below 7" strips with hot glue.
From craft foam, cut six more strips, 1/2" x 8-3/4". The strips are exactly like the above 7" strips for the first seven inches, but take note of photos 11-13 above. From the 7"-point to the 8-3/4"-point, the end widens from 1/2" to 1". Glue these strips to the PVC below small squares, leaving the widened 1-3/4" sections loose at the base
Step 6: Finishing the Handle Trim
From EVA foam, cut a hexagon shape with 1" sides.
Using a forstner bit, drill a 1" hole in the center of the hexagon. This could also be done with a utility knife.
Slide the hexagon onto the end of the PVC pipe, fitting it snugly underneath the loose ends of the strips.
Glue hexagon to the pipe. Glue loose ends of strips to hexagon. (See photo 3.)
Glue two scraps of EVA foam together.
From this piece, cut 1 triangle with a base of 1" and height 2-1/4". Glue this piece onto the end of the PVC pipe using hot glue.
From craft foam, cut 4 triangles with a base of 1" and height of 2-1/2". Glue these four triangles around the EVA triangle. (See photo 6.)
Cut a 9-1/2" x 3-1/3" rectangle of craft foam. Glue this piece around the remaining showing length of PVC between the flange and the pointed end.
Step 7: Painting
Finally, paint the craft foam black, using a brush and craft paint, or black spray paint.