DIY Crusader Flail

crusader flail 1

Need a cool prop you can pair with a number of warrior costumes? Then a flail might be just what the doctor ordered. Instructables user JackieC29 crafted one based on a design used by a character in Heroes of the Storm, but it’s a versatile weapon. She made it from Worbla, polystyrene foamboard, wood glue (to seal the Worbla), EVA foam floor mats, and a few other supplies that are relatively easy to get from your local hardware and craft stores.

Here’s how she made the handle:

I grabbed a dowel rod from Lowe’s and cut it to what I guessed was the right length with a jigsaw at my desk. I stared at the image reference and wrapped foam around where I assumed each different round part would be using just the EVA floor mats I cut into strips. I knew I would cover this in worbla later so it would be super strong and so I didn’t have to be too clean with the edges.

I added smaller strips of the craft foam around to create the layered effect and also covered them with worbla.

I wrapped the center grip with a piece of craft foam to build it out a bit and to be able to use my wood burning tool to create the indentations for that faux leather effect the handle has. As you can see at first the handle was quite messy with the use of the wood tool but I then cleaned it up with a little sanding(that’s a cool perk of worbla is that you can treat it exactly like wood!)

crusader flail 2

crusader flail 3

Get the complete how-to at Instructables.


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