I need a massive tube, any ideas?

Sheet metal will be lighter than cardboard, polycarbonate, fiberglass, or paper mache. Use JB Weld epoxy for the seams and joints and tape in place while the adhesive sets. You can use aluminum or galvanized steel depending on how strong you need it to be.
 
Concrete tubes do come in those diameters, just not at Home Depot look for a local building or contractor supply place. Also checkout any form supply places.

As I said, at that size, they appear to be incredibly heavy. If a 12" diameter tube is 2lb per foot, 36" would be 10lb per foot, and at 4ish feet, that is 30-40 pounds.
 
Here is something I thought of today that would be cheap, very sturdy, and fairly light compared to other options. I could build a PVC frame and add cardboard to the ends and fabric of other material around that to give it the shape we want. hammer.png
 
Here's what we put together based on the design above. I am short a 4-way joint. We went with a 1.5" for the center for weight, and we need to cut it down a bit to make it fit and to put the T joint in the center. I think, to be mobile, because it won't fit out a door, we're going to build two "lids" out of corrugated plastic and glue snaps inside them, then use wood print fabric to snap between the two. The plan is to add zippers to the bottom of the fabric where the handle inserts. I'll glue some parts of the PVC, so we can disassemble it to travel. I need to get a 1.5" threaded insert and female insert to attach at the T joint so the handle screws in.

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i'm gonna try and use my psychic powers and guess your building a huge hammer for a harley quinn cosplay outfit.:ninja
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that being said....i'd build it out of foam then wrap it in cardboard and paint it to look like wood.
 
i'm gonna try and use my psychic powers and guess your building a huge hammer for a harley quinn cosplay outfit.:ninja
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that being said....i'd build it out of foam then wrap it in cardboard and paint it to look like wood.

i thought the same thing. But the OP stated he had thought it was never done before. I follow more than half a dozen women on Instagram that already do this.
 
This is a vanity thread right???.........You're building a prop that won't fit through any door, you wont' tell us what it is and have ignored most of the advice posted....??

Don't get me wrong.....we'll support you as best we can....but seriously....

Wait, what costume that isn't for sale isn't a vanity project?

I really like this community and appreciate all the advice that is offered. I've used several suggestions, in some manner, in this thread. However, following the more specific posts entirely didn't work well.

Most of the advice has been ruled out due to weight. You can read that yourself, man. We went out and tried a lot of the ideas posted here, and they were either too heavy, too pricey, or not stable at all. I've also seen dozens of projects here in which people won't specify what the prop is, what character it is for, or if they didn't post info as they went along, how they made it. This is hardly new.

As for fitting through doors, the idea is to make it so it comes apart. I won't be pedantic, but I did say this in the post just above yours.

CharlesHouse said:
I think, to be mobile, because it won't fit out a door, we're going to build two "lids" out of corrugated plastic and glue snaps inside them, then use wood print fabric to snap between the two. The plan is to add zippers to the bottom of the fabric where the handle inserts. I'll glue some parts of the PVC, so we can disassemble it to travel.

.i'd build it out of foam then wrap it in cardboard and paint it to look like wood.

We tried that. At this size, it required a lot of foam and became very heavy. We almost bought 40 or so yards of batting on a roll and covered it in cardboard, but it would have been nearly $100 for foam alone, on sale, and still require finishing. Without a skeleton of some kind or being entirely full of foam, at that size, foam and cardboard wouldn't be stable. That's when we went to building a frame.
 
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If cost isnt to much of an issue.

Use wire to form hoops, then make into tube with dowel or garden canes. To finish use the tissue and dope method or heat shrink plastic that Model aircraft is made out of. It will be very light, you can paint it, it wont take as rough handling as cardboard but will do the job.
 
If cost isnt to much of an issue.

Use wire to form hoops, then make into tube with dowel or garden canes. To finish use the tissue and dope method or heat shrink plastic that Model aircraft is made out of. It will be very light, you can paint it, it wont take as rough handling as cardboard but will do the job.

Cost is an issue; I've ruled out a few options because of it. I appreciate your post, though as you can see, I've built the frame and have a basic outline of what needs to be done. I've ordered fabric for around the cylinder, but I need to find a source for material to make caps with, for either end, that are sturdy enough to attach the fabric to with snaps on the inside. Coroplast seems good, but I have never worked with it. I'm thinking:
frame.jpg

I'm posting these as I go because I appreciate in insight of the great people here. I'm sure there is insight to be had, and clever ways to make this work that I haven't thought of.
 
I needed a port diameter that didn't exist so I used my perfect circle jig on my router and cut dozens of MDF rings and glued them together . You can certainly build a circle jig easily enough to accommodate a wood router and cut out and size circles you'd like .
And even if you don't want to make dozens of rings , than maybe you could use them as a support and fiberglass construction paper or some other material to them . Just a thought
 
We considered that, though our access to tools is very limited. We recently moved from rural areas with access to tools to the city. I have seen a few hammers made by hand-cutting foam, but they look rough.
 
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