Honestly, if you know how to work with fiberglass, that would be the ideal way to go, and would only cost you about $30 or so.
Other than that, you may look into polystyrene (Styrofoam). The thing is that you have to coat it with a plastic when you get the final shape, or it
will break the very first time someone else draws their sword on you. There are spraycan plasticizers, but you'll have to order them which would
probably take too long.
I would suggest visiting your local art & craft store and asking them... just don't let them talk you into anything cheap like cardboard. Lol... if
you were in Cheyenne, I'd just help ya make one... there's hundreds of products you could use.
EDIT: Just thought about it... use the foam for a base material, then use the above mentioned paper mache. The main problem you will have is the mache
buckling from not adhering to the foam, though... so you may look at something paper-based that you can use for the main shape. When you get done with
the mache, get a high-build primer and use many coats, then sand it smooth... as close to exposing edges of the paper as possible without actually
going INTO the paper. Then you can spray one more coat to check for smoothness, and then continue with the colors you choose. The primer will ensure
that your paint doesn't chip everytime you clash weapons with anotehr... and steel colored spray paint just looks awesome when it's done right...
once it's dry, spray on some black and wipe it off really fast to give it an aged and battlescarred look!
GL!
[edit on 15-6-2008 by Earthscum]
