8)Gaffi Stick
Again, no progress pics but I will try to explain what I did as best as possible. I shaped the wooden shaft from a 2x4 about 3 feet long. I cut out the general profile on a bandsaw, roughly sanded it and then routed all 4 sides with a 3/4" roundover profile bit, thus creating a round shape. There is a slight bend about half way up and another near the club end. All transitions were sanded smooth. I drilled a hole in the end to accept a 7/8" diameter electric conduit pipe, about a 18" long. I used some threaded inserts for this so the whole thing can come apart and break down for travel. The mace end is 1/8" sintra cut to shape and glued together to form an X. The pipe was slotted to fit this and the whole thing is kept in place with a 3D printed retaining ring. Dabs of hotmelt were used to simulate welds.
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I made two club ends, one 3D printed and one was carved out of a foam floor mat so it is soft. Same with the spike, one is maple hardwood and the other soft foam for safety. I can easily swap these out as they are all threaded.
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I painted the wood with some stain and acrylic and rubbed it down to simulate wear. The soft ends were sealed with some Modge Podge and painted with acrylic spays. The silver ends were randomly painted with two colors of silver, dusted with black, brown and sand color, lightly sanded with a scotchbrite pad and then the edges were hit with a silver pen. The shaft was wrapped with some rope to add interest and act as a grip.
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