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Here's my design:


I'm gonna make a mock up out of cardboard, but I was wondering if anyone had thoughts on how to make it sturdier.

Any advice on making this sort of thing is welcome, links too. Thanks!

3mm sintra would probably be your best bet.

It also depends if you want the "blades" to spin.

get an old carbon fiber fishing rod {the thick end} strip everything off cover each end in gaffer tape.
get some pipe insulation and contact adhesive coverthe rod in the foam insulation.
with the glue then get a camping mat
and cut out the shapes with a stanly knife .useing the adhesives to glue each bit together you mite need 3 or 4 bits and sandwitch the shaft in beetween them
have a google for larp axes and theres loads of guides out there.

Cool, thanks. I do want the blade to "spin" but it's not a must.

I would use Sintra aka PVC expanded foam for the body, it's what I use on most of my projects.

I don't mean to threadjack, but here is a link to my thread where you can see the items I have made using Sintra and my motorized chainsword project.
http://www.dakkadakka.com/dakkaforum/posts/list/284267.page

You might find them useful in building yours which I look forward to seeing!

Edit: forgot the link

I saw your thread. It blew me away. I found it looking for inspiration for my axe. I was wondering what you had used for the armour. I haven't had time yet to do more than look at the pics. I'm gonna make a dreadnought power fist too.
I'm gonna start on a cardboard pair first, so I can get the hang of it. Maybe work out some template that I can print out. Do you use something like that, or freehand it most of the time?

Didn't think hot water would be all I needed. It doesn't have to be boiling or anything, right?