Part Five

I line the inside with foam while I try to decide what exactly it is I want to do with that interior and later I carve wood grain into the exterior.

(Look here for the previous part to this build)

This is where I left off from before.

The whole exterior is now covered with EVA foam.

I did some measuring and cut some thin foam to line the inside of the mallet head.

I took a can of spray adhesive and used it to apply this foam to the interior wall.

It fits a bit awkwardly with the handle going through there like that.

This will take a bit of work to lay this down flat.

Some smoothing out and pressing is required to get it in there right.

There will be a bit of cutting as well to get everything to lay down flat around this handle.

As I may have mentioned in a previous post, the idea of utilizing the interior was a last minute thing.

I just thought that it would be cool if you could keep some things like a wallet or phone or keys or a beer or your weed inside there while you are actively using it at an event or some convention you may be attending while in costume.

Now that I have it all covered, I set it aside to dry.

I am a little disappointed that I didn't get the actual shots of the Dremel tool being used.

But here is the result of me running a Dremel tool over the mallet head. I was trying to achieve a more wooden-looking appearance.

I also used the tool to inflict intentional damage particularly around the ends of the mallet head.

I also cut some strips from my thickest foam to make bands that will wrap around the mallet head. Now with these bands, the thin bands I already had around the ends now disappear and the mallet now has a subtle flared-out angle to the ends.