Forged From Paper and Cardboard: Crafting a Medieval Mace

Step into the world of medieval craftsmanship with this DIY project—an intricately designed medieval flail made entirely from humble materials like cardboard and paper. Whether you're a history enthusiast or simply a creator at heart, this project transforms everyday supplies into a striking piece of weaponry.

This project only uses a few simple materials:

1. Paper sheets
2. Scissors
3. Clear tape
4. Hot glue
5. Cardboard tubes (such as toilet paper rolls)

Take a sheet of paper and begin rolling it from one edge to the other lengthwise, keeping the roll as tight as possible for added strength. Apply steady pressure as you roll to ensure a firm and uniform shape. Once the paper is fully rolled into a tube, secure the edge with clear tape, wrapping it around multiple times to reinforce its structure. If additional stability is needed, consider adding another layer of paper around the tube and taping it down for extra durability.

Take a piece of paper and tightly crumple it into a compact ball, applying firm pressure to ensure it holds its shape. Then, take another sheet of paper and wrap it around the ball, pressing and shaping it as you go to maintain a rounded form. Repeat this process with additional sheets, layering them gradually to increase the ball’s size and density. I used three sheets of paper total, but you can use as many as you want. Once the desired shape and sturdiness are achieved, wrap the entire surface thoroughly with tape, smoothing out any wrinkles or uneven areas as you go. This final layer ensures a solid structure and a clean, polished appearance, ready for the next stage of adding the spikes.

Taking a sheet of paper and starting at one of the corners, roll it tightly into a compact rod, keeping the shape firm as you roll. Once it is completely formed, secure the entire length with tape to ensure it holds together. Next, take a pair of scissors and carefully cut the rod in half to create two shorter sections. Take one section and bend it into a circular ring, adjusting the shape to form a smooth loop. Tape the ends together securely so the ring maintains its shape. Repeat the process to create multiple rings, each one linked through the previous ring before taping them shut. Continue attaching more rings to form a chain, reinforcing each connection with tape for durability.

Take one of the half paper rods and gently bend it into a U-shape, ensuring the curve is even and smooth. Next, position the U-shaped piece against the handle, aligning it where you want the chain to attach. Secure it firmly to the handle using multiple layers of tape, wrapping around both the handle and the curved piece for extra stability. Before finalizing, attach the chain by threading it through the U-shaped piece, ensuring it can swing freely while remaining secure. Once everything is in place, reinforce the connection with additional tape to prevent it from loosening over time.

Take a pair of scissors and carefully cut a small hole in the paper ball, ensuring it is just large enough to fit the end of the chain. Once the opening is prepared, flatten or smash the end of the chain. Insert the smashed end into the hole, positioning it deep enough for a secure hold. Next, apply hot glue generously around the chain’s end inside the ball, making sure it adheres firmly to the surrounding paper layers. Allow the glue to dry completely before testing the connection, ensuring the chain is securely attached and can swing properly without loosening.

Take a cardboard tube and carefully cut it in half using scissors. Starting from one of the corners, begin rolling the piece inward, gradually forming it into a cone shape. Apply steady pressure to maintain a smooth curve, adjusting as needed for symmetry. Once the desired cone shape is achieved, secure it firmly with tape, wrapping around the seam to keep it in place. Using scissors, trim off the narrow end to create a smooth bottom surface. Repeat the process to craft multiple cones.

Apply a generous amount of hot glue to the base of each spike, ensuring full coverage for a strong bond. Carefully press the spike onto the flail head, holding it in place for a few seconds until the glue begins to set. Repeat this process for each additional spike, strategically placing them around the ball to achieve the desired pattern. Once all spikes are attached, allow the glue to dry completely before handling the flail. For extra durability, reinforce the connection by adding another layer of glue at the base of each spike.

To reinforce the handle for extra durability, take another cardboard tube and carefully cut it in half lengthwise. Once divided, roll each half into a tight tube to ensure it fits snugly inside the main handle. Slide the pieces into the hollow handle. If necessary, apply a layer of tape or glue to secure the reinforcement in place and prevent shifting. This added strength will make the handle sturdier and more resilient during use.

And just like that, you've crafted your very own medieval flail! Swing it with pride, test its movement, and admire the craftsmanship you've put into it. Whether you're using it for play, decoration, or just for fun, it's a fantastic creation made entirely from paper and cardboard.