Kagamaru's Tusken Warrior Build Thread

[Nezhdanov]

That’s looking great!

I would only suggest shortening what the beads hang off as the beads seem to hang dangerously close to your feet and could be stepped on which could send you flying and undo all that bead work!

And I think I can see your hand through the o shape of the gloves. Maybe just a piece of the black wrap material on the inside of the glove will sort that?

See what you think but that’s all I have apart from saying that it’s looking like a really great costume [emoji4]


Sent from my iPhone using Tapatalk

[Kagamaru]

Added some wraps to the gloves and sewed a few links of the apron to the Obi. It hangs a bit higher now. I think I’m ready to go for approval. No gaffi yet. That’s going to be its own process and I’m still looking for a vendor to help me with the production of my model. 
 

 

[Nezhdanov]

Well I think you’re ready!

The gaffi is an accessory so not required for clearance. You can add it later, it would be great if you added the gaffi build here to complete the costume [emoji4]

All the best with it and let us know how you get on!


Sent from my iPhone using Tapatalk

[Kagamaru]

Absolutely will continue the build! Must leave a record for those who come after.

 

 

 

[Kagamaru]

Approved! Thank you, Nezhdanov, for hanging with the build all the way through and giving so much valuable feedback! Started over 4 months ago as a “quick build.” lol I should have known better. I’m very happy with the finished work and can’t wait to get trooping. Next up is the gaffi. 
 

 

 

[Nezhdanov]

Congratulations!

Well done on completing the project and doing a great job on the build.

Hope you have a lot of fun with it [emoji4]


Sent from my iPhone using Tapatalk

[Kagamaru]

I’m back and more dangerous than ever! I’ve been working on a gaffi stick since May. It’s almost complete. I got a local wood craftsman with the proper tools to use his lathe to turn the basic pineapple shape and rough in the staff. Here’s the process of finishing it out. The wood is black walnut with the pineapple end made from the heart of a local recovered downed tree straight from the heart where the cleft of the tree had conjoined. 
 

 Lots of sanding to get the staff to a diameter comfortable to hold. 


 

Experimented with several ways to make the vertical cuts. File was too slow, dremel wasn’t precise enough. So I wound up using a chisel. Worked like a charm. 
 

Could have used some sort of clamp to hold this while chiseling. Was very awkward. But managed it. 
 

Sanded down the end to a peg to fit the spear end.

The woodworker left the angled end really big. I had to remove a lot of material and sanding was just taking too long. After a bit of research I discovered a rotary bit I could add to my angle grinder specifically made for wood.

If you go this route PRACTICE! It will just melt through the wood. Hot knife through butter. Clamped the staff good and tight to the table. Also a must.

After a ton of sanding I installed the pineapple to the staff with a bolt stud that I cut the head off of.

Hole in the pineapple end. The gouge was filled in later with filler. Whoops, that angle grinder wheel means business!

 

Attached pineapple. Just screwed on with a bit of wood glue in between.

Wood filler that claimed it was stainable. It was not. Eventually had to use sharpie to color it in.

A little reconstructive surgery.

I made my own ebony stain by soaking steel wool in distilled white vinegar overnight to make iron acetate. When painted on the wood it reacts with the tannins and turns a rich black color.

 

 

 

 

https://imgur.com/a/MPd0WVS#U9GKVRA
Video ^^^
Used the Dremel to make the textured grip area near the head of the piece.

 

The leather grip at the end. Buffalo hide with sinew thread. This was a challenge. I measured but maybe due to the thickness of the leather it came out a little short. Had to pull the thread really hard to close the gap. But managed to get it closed. It will never slip! 
 

 

The end has been a challenge. I built it in a 3D program with the intention to have it cast in aluminum. I just couldn’t find anyone who could do it and it’s too tall to 3D print in metal not to mention crazy expensive. So I printed it in PetG for durability and sanded/painted to replicate a metal finish.

https://imgur.com/a/MPd0WVS#Zk1Zpva
 

Video^^^

 

 

I have a little filling to do around the cuff between the spear point and staff. I might also put a couple screws through the collar into the wood peg to secure the end better. It’s pretty tight as I used a bit of leather around the peg to fill the collar tight. Then will call it done. Hope you like it!

 

 

 

Edited July 25, 2025 by Kagamaru

[Nezhdanov]

That’s a good effort! Well done for going all in on recreating the gaffi!


Sent from my iPhone using Tapatalk