10-Foot Halberd
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10-foot (3m) Halberd for stilt costume - Includes anti-skid foot to provide support as a walking staff.
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- Creative Commons — Attribution — Noncommercial — NoDerivatives
10-Foot Halberd for stilt-walker costume use - Includes traction pad in foot so it can be leaned on for stability.
WARNING: This a prop, not a toy or for play fighting. This design has pointy bits that could cause severe injury or blindness by someone walking into them or the prop falling on a person or animal. Dilligent care and awareness must be taken at all times when handling any props with pointy bits.
I printed the head from PLA (3mf split for Core One included), the foot from PETG for durability, and the footpad from TPU for traction.
Needed Hardware:
- 1-1/4inch (35mm) Schedule 80 PVC Electrical Conduit - Use length as appropriate for character height
- 4 1-inch (25mm) Drywall Screws (length is not critical, similar sized wood screws will work fine)
Assembly:
- Glue together the pieces of the head (unless you have a massive printer and can print it all in one go). Fill gaps and paint. I used drywall spackle to fill gaps, sanded when dry, then sprayed with a coat of sandable primer, which helps hide layer lines after a light sanding, then a hammered metal finish spray-paint.
- Paint the foot and screw covers at the same time.
- Decide on pipe length and cut to length. Sand the pipe exterior rough sandpaper. This will help paint adhere and give a bit of woodgrain texture. Spray paint the pipe. Optional - After the paint has dried rub some black acrylic paint into the scratches left behind by the sandpaper for even more of a woodgrain look.
- Glue the flex tread into the foot with a glue that will bond to both plastic and rubber (E6000, Shoe Goo, etc.). Be sure to smear the glue into the holes in the foot cup and the top of the flex tread, they are there to support mechanical grip of the glue.
- Slide the foot onto the pipe. Drill a small pilot hole in the pipe through one of the foot's screw holes, insert a screw, then glue a a foot screw cap on over it (note, be sure to line them up correctly, they are not fully symmetrical). Repeat with another screw and the other screw hole.
- Slide the head onto the other end of the pipe and secure it with screws, covering them, the same as the foot.
Be careful.
Have fun.