The Sweatshop

Well-Known Member
RPF PREMIUM MEMBER
Unfortunately a lot of this build will lack photos. My phones back facing camera is broken and add on a lack of discipline of taking progress pictures of the build. It's far too fun building to pause the build to take photos.

Lets start with end goal and references.
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When it comes to costume/pattern making, I tend to be more comfortable working in 3D rather than paper and scrap materials. I've 3D modelled most of the props including the backpack for consistent scale. As far as gaffi sticks go, I'm starting with the totokia. I have a woodworking friend that is taking on the wood part while i am tasked with the steel end, though I might take on tribal engraving just to add more "flavor" to this build, and I do plan on having the pinecone/pineapple texture on the head of the totokia, though the figures lack that detail.

Also, I know there are other on-screen gaffi sticks that might be more desirable to own, but I am building to make accurate to the mythos figure, with features from the static figure being priority, taking details from the posable figure only if I feel that it adds to the final build.

If this build goes well, and If my woodworking friend is up to it, I might go after other totokia gaffi sticks, I'm interested specifically ANH tusken and Boba Fett's.

Without further ado lets see some progress shots.
 

The Sweatshop

Well-Known Member
RPF PREMIUM MEMBER
Starting with my 3D model and drawing. I did this months ago, maybe over a year. Last couple of years have been a trip.
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The Sweatshop

Well-Known Member
RPF PREMIUM MEMBER
Has anyone ever ID'd the real thing used for that flat bladed version with the more ornate "mace" head?
If you’re talking about the wood parts, this is a good resource about the war clubs
If your talking about the metal parts, I imagine wit was scratch built from a “box of scraps”
 

The Sweatshop

Well-Known Member
RPF PREMIUM MEMBER
I forgot to mention, I don’t have access to a machine shop currently so this will very much be a garage build. That being said I do think replicating a gaffi stick is prime for this if you’ve seen how the originals look.

Uncle had some 1/8th inch flat stock steel perfect for what I’d call the arrow fletching.
This area
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Made a stencil and marked them out on the flat stock and rough cut them on my vertical bandsaw. Seared my finger tips though grabbing the piece without using any cooling fluid, ouch. After cutting them out I CA glued them into a stack and took them to size on the grinder and belt sander. Left some of the pitting that was on the sheet stock since at this point I liked how they look out and why make it perfectly pristine just to heavily weather it later.
Some pictures to illustrate, though I took them after doing all these steps
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The Sweatshop

Well-Known Member
RPF PREMIUM MEMBER
Started working on the washer pyramid piece.
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Went to ace hardware and picked up a lot of washers and some more just in case I messed a few up, which I’m glad I got extra! Their holes where 1/4 inch and so I marked their intended diameter in mm.
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Locked them up on a 1/4 20 bolt and chucked it in a drill and used a grinding wheel to get them into size.

After stacking them I realized that the stack was about 17-18 mm and my drawing was 20mm. Which to some it doesn’t matter, I’m mostly chasing dimensions I made up from the figure. But with this part I decided not to fudge the dimensions and stick to my drawing as is. Grabbed a local grocery ad and cut and stacked 13 tiny squares of the thin ad paper and added it atop the pyramid and alas 20mm. I CA glued each washer with a paper in between and clamped them to dry.
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I need to still drill out the center from 1/4 to 3/8 since that’s the bolt size me and the woodworker chose for mating with the wooden totokia.
 

Sluis Van Shipyards

Legendary Member
If you’re talking about the wood parts, this is a good resource about the war clubs
If your talking about the metal parts, I imagine wit was scratch built from a “box of scraps”

Ah okay, I didn't know the flat one was also from Fiji.
 

The Sweatshop

Well-Known Member
RPF PREMIUM MEMBER
Should’ve posted some updates, I’ve got some photos in the queue.

Took a break from pyramid to work on this one.
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I couldn’t really find something that was close to this, especially in the bigger diameter and length.
I decided to break it up into three parts. One 1 inch bushing and two 1 1/4 shaft collar.
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I started sizing the individuals pieces height with this jank @$$ rig to keep it fairly square, I don’t remember where I put the fence that came with the grinder, since I’ve barely used it.
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Got it sized up and started glueing parts together to it ready for some tapering.
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Also tightened the set screw on a 3/8 bushing so everything will be consistently using that internal diameter, and welded the hole, though it’s had some pits and gaps. Also put the part on a 3/8 bolt, tightened everything up and chucked it in my drill since I’m going low tech, no lathe on this project. Spun the part and ground into shape on a grinder.
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Got bored and busted out all my sandpaper levels to see how chromey it could get, though I will reweather it once all metal parts are assembled.
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Sluis Van Shipyards

Legendary Member
I love seeing people doing stuff like this by improvising with their tools. Since most of us don't have lathes, these posts show a good (hopefully safe- ish? :lol:) alternate way of doing something.
 

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