Prop help!

[MistressLegato]

I have limited prop-making experience with my cosplay as most chars I've done didn't require them.  HOWEVER, this year my cosplay will be:

http://www.deviantart.com/view/8787113/

and I need some hints as to how to go about making this:
http://www.fanfic.net/~dragon/Saturnpics/dropglaive.jpg

prop.

Cardboard is out of the question, it's flimsy and bends.  What would an expert prop-naker suggest?

[Vondan]

I'd be tempted to want to make it in Aluminum to save weight for such a large blade (I once sand cast a beautiful bronze double axe head with ruins just like He Man’s but it weighed 50 pounds.)   But for cosplay you could use Urethane foam insulation sheets.  It can be carved with a knife or a hot wire cutter, in the past I had carved daggers and axe heads out of it then used them to sand cast mettle.  The do dads on the bottom of the spear you could find something like that off fancy curtain rods.  


Look around for cosplay sites with tutorials.   I’m researching this stuff my self as the weapons I have made in the past were to real for cosplay except the nerf daggers for Julius Caeser  


http://amethyst-angel.com/cosplay.html

[ObiJay]

I'll second the above site. It's what allowed me to make this thing



In the span of two nights before Sakura Con, after my first sword broke.

[pinkrandomattack]

theres alot of stuff you can do with wonderflex and pvc piping, they sell the flex stuff on cosworx.

[Miss Citrus]

And I'll third Amethyst Angel's site, especially the page she references for weapon making. The plastic and foam method holds a huge amount of possibilities; I made gratuitous use of it for my costumes (and my friends') for Sakura-Con. ^^

BTW, I love your Eternal Sailor Saturn design. Can't wait to see it. x3

[MistressLegato]

Thanks a TON you guys!  My heroes  I'll be proud to show it to you all at the con!!!

[Vondan]

And I just realized the other day when some one showed me a picture of a rubber axe head that looked like it was 3 layers glued togeter I could try to use some mid sole material it comes in sheets of ruber 3 feet long and i inch thick