Mod Shop – Melee Staff

As an aside before we kick into the actual post this week, I’d like to take a moment to plug my upcoming run. On the 12th of August this year I’ll be competing in the City2Surf. For those of you not from Australia, the City2Surf is one of the largest running event in the country, drawing thousands of people every year to run from the Sydney CBD to Bondi Beach. If you’re feeling particularly generous, pleas head along to my Fundraising Page and make a donation. All proceeds go to charity and I’ll need all the support I can get to actually survive the 14km.

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Another homemade this week but one that’s a little different in that it’s not a blaster at all. As the last two posts have eluded to, we ran a GoT themed game last weekend which included melee weapons. I’ve got a pair of short swords that I normally run with for these games, but decided I wanted something a little longer for this one. Thus, the FDG Staff was created.

Specifically I made a double ended staff, but the method could be applied to practically any melee weapon you want.

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Tools/Materials required…

Foam floor mat
Fibreglass rod
Knife
Hot glue + gun
Rope
Duct tape
Yoga mat

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To start with with have a floor mat.

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Trim the jigsaw sections off the sides, cut a piece the length you’d like for the striking zone and mark for four equal widths.

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Cut into said four equal widths. These won’t ever be seen so they don’t need to be perfectly straight.

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Grab your firbreglass rod, lay it over a piece and mark the edges of it.

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Like so. Do this for all four pieces.

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Create another mark across 25mm in from one end on each piece, then another mark a further 25mm in on two pieces.

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Then cut out the marks we’ve just made.

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Test fit that they nest together.

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Tape the core.

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Remove the core, leaving the tape intact.

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Slather with hot glue, reinsert the core then cover the top with hot glue too.

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Cover both sides of the core hot glue and slide over the other piece of foam.

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Should leave you with something like this.

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Do the same to the other end.

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Cut four more strips of foam the same length as your striking areas, roughly half as wide as the previous ones.

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Glue them in-between two sections on opposite sides.

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Then wrap the whole thing in tape.

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Should result in something like this. I’ve also used offcuts of foam to help strengthen the joins.

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Cut an end cap and glue/tape it into place.

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Glue one end of the piece of rope to the inner end of one of the striking sections.

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Then place a layer of glue around the base of the core and tightly wrap the rope around it.

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Continue wrapping the rope around. Ensure it’s as tight as it can be, this isn’t good enough.

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Wrap it the whole way down the core.

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Then cap it off by gluing the far end.

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I missed some photos here unfortunately but it’s pretty simple. I cut a yoga mat to size and taped it to the foam.

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The yoga mat is far softer than the foam flooring.

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Pay careful attention to the end cap. Put a good 4-5 layers on here as you will be striking with it and you don’t want to impale people.

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Finally, loosely wrap the yoga mat in duct tape and we’re done. Doing it tightly will compress the yoga mat and make it harder so make sure it’s relatively loose. You can also see here my short swords and my ball and chain. The swords were made with the same method; floor + yoga mat over a fibreglass rod core with a rope wrapped handle. I might do a write up on the chain someday if people are interested.

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2 thoughts on “Mod Shop – Melee Staff

  1. I’m so going to do the staff for my brother and I would love to know how to do the ball and chain for myself 😛

    • Can do. I have a go at it eventually.

      Abridged version; plastic chain threaded with rope for strength, attached to soft foam soccer ball. Be particularly careful when attaching the ball to the chain as it needs to be a strong join, but can’t be able to hurt someone.

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