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I'm thinking of building a crowbar prop this year so even though I'm too lazy to make a new costume at least I'll have a decent upgrade. Do you guys think I could get away with building it from plywood?  I'd hate to go through the trouble and not be able to carry it around.


- Edit -

Alright I've got my game plan. I want the challenge and I want it to be fairly sturdy so I'm going to make it out of plywood and paint it. Materials, tools, and procedure below.

Materials

[table]
[tr]
[td]3/4"x2'x4' plywood[/td]
[td][Image: x7pvQTus.jpg][/td]
[/tr]
[tr]
[td]wood glue[/td]
[td][Image: IuZwi24s.jpg][/td]
[/tr]
[tr]
[td]spray paint
  • "hammered" black spray paint
  • red enamel spray paint
[/td]
[td][Image: ExqSn6us.jpg][/td]
[/tr]
[/table]

Tools

[table]
[tr]
[td]circular saw[/td]
[td][Image: cEJWZO1s.jpg][/td]
[/tr]
[tr]
[td]wood clamps[/td]
[td][Image: KlIpMzCs.jpg][/td]
[/tr]
[tr]
[td]Jigsaw[/td]
[/tr]
[tr]
[td]power sander[/td]
[/tr]
[tr]
[td]dremel[/td]
[/tr]
[tr]
[td]sand paper[/td]
[/tr]
[/table]

Procedure

Completed:

Measure and saw 3/4" plywood in half
[Image: KCeS0Ihl.jpg]
[Image: YVBbgNdl.jpg]

Apply wood glue and press both halves together on top of each other
[Image: aObmcWpl.jpg]

Clamp until glue dries
[Image: CVcL39Gl.jpg]



Planned:
  • Trace crowbar template on plywood
  • Cut out crowbar shape from plywood with jigsaw
  • Sculpt details with power sander
  • Sculpt fine details with dremel
  • Sand until smooth with sandpaper
  • Apply three coats of black spray paint
  • Mask both ends with tape and apply two coats of red spray paint to the "handle"
While high density foam would be the best option, you could make a crowbar from a single 2x4. Saw table to rip down to size, jig/scroll saw to shape the ends and a router to give it a hexagonal shape.
I wouldn't suggest using foam unless you plan on coating it with fiberglass. Foam props ding really easily and it's annoying to the point where I want to remake all my props out of wood. Plywood should be fine; I wonder if you can get away with carrying an actual crowbar. I wonder if I can get away with carrying a real frying pan...

Long and skinny props break more easily when made from foam.

source: personal experience :'(

Edit:

The Prop Acceptability Checklist
If you can answer yes to any of the following questions, the prop is not allowed.

    Is the prop longer than the congoer's height when carried, if the congoer is at least 4 feet tall?
    Is the prop longer than 4 feet when carried, if the congoer is less than 4 feet tall?
    Is the prop made of live steel?
    Is the prop a real firearm?
    If the prop is a gun-like prop, does it lack an orange tip?
    If the prop is an gun-like prop, is it not disabled and unloaded?
    Are there projectiles loaded or nocked into the prop or easily accessible on the prop's carrier?
    If the prop is a water gun, is there water in the reservoir?
    If the prop is a bow or other stringed weapon, is it tightly strung?
    Are there any loose arrows or bolts with the costume or prop?
    If the prop is a sword-like prop, is it being carried in a dangerous manner?

Seems like if you didn't want to make a prop crowbar, you can just bring a real one. Unless crowbars fall under the "live steel" category.

rumsfald

(04-27-2013, 11:55 AM)Käse link Wrote: [ -> ]Long and skinny props break more easily when made from foam.

source: personal experience :'(

rip liquid's kukri
Step One:  Purchase Crowbar
Step Two:  Paint the tip of said crowbar orange.
Step Three:  Bring it to Con. 
Step Four:  Profit
Whatever you do, do not bring an inflatable crowbar, they will tag it