Well, I can pretty much guarantee this will not be done in time for Halloween this year, Will most likely be staying as a scarecrow like last year.
The Ren Fair next year is my ultimate goal. After studying many different ways to do things, I have decided to tackle this feat, and hopefully turn some heads when it is complete. The main reason I am opting to build it myself is the weight factor, but the money being saved vs the metal counterparts will be nice too
I am basing alot of it off of the expensive blacksmith replica work that most people are familiar with, but I am not going for an exact movie replica:
The rags/robes will be last on my agenda, as the armor and mace seem to be the difficult pieces.
As for the gauntlets, arm-guards, shoulders, etc.; I will be tackling them much later as I will most likely be doing those in plasticard since it is much more intricate, but I have practically no experience working with plastic at the moment. Was originally going to do them with cardboard but after seeing http://www.therpf.com/f24/wip-witch-king-angmar-86074/ I had a change of mind. There is a chance I will do them with thin sheet metal, as my girlfriends dad has tons of metal working tools collecting dust.
For my first project, I am doing the flail, followed by the helm.
Both of these will be cardboard/bondo creations.
Skeleton for the flail so far (only 4/8 spike sets cut out/ held up pic):
(hid the messy room )
I have a test of spray foam setting to see how easy it can be carved/shaped, but if all goes well, I plan to spray-foam fill around the skeleton, carve the spray foam to a rough shape, then bondo for the final shape/texture/durability. However I still need to get a wooden dowel for the core so I can have something to screw the chain hook into that wont pull through, and give it a bit more durability.
Any thoughts and opinions are always appreciated, as this will be a lengthy task with most likely tons of trial and error.