I’ve had a request to make a hammer for Fulliautomatix in the Asterix game: a big, rectangular block on the end of a stick (would also do for a comic-book style Mjolnir). Any hints?
From browsing around a while ago, I understand that the standard method for this type of weapon is to use a block of open-cell foam around the core, then clad it in closed-cell to give a latexable surface. My concern is that the different compressabilities of the two types of foam is going to cause a lot of stress on the outer shell when the weapon is used, and possibly cause it to pop a corner or side. Does anyone have any experience with making this sort of weapon?