I'm working on a sonic rifle for my annimated Fett costume and I need some help. The rifle is made from 2" thk. blue board and sanded down into shape. I've used wood glue to hold the pitchfork part on but I know its a little weak. I'm thinking about inserting a dowel rod and then glueing it. Does anyone know of a good "glue" that won't eat the styrene? I even thought about bondo-ing it and sanding it but I'm not sure.
Also, once its complete, I thought about making a mold and casting it out of resin. I've never done that before so I don't know if it'll work. Anyone having any insight please post your thoughts.