by stormtrooperguy

This is my 3rd revision on the Gaffi stick model. After trooping with it a few times I had some areas I wanted to improve on.

1. The core is now a 1" dowel.  This makes it more rugged, and the print uses less filament since the opening in the middle is bigger.

2. The tolerances are tightened up, so the fit of the parts should be less sloppy.

3. Alignment holes for parts that were tricky to glue correctly. Use 1.75mm filament or 16 ga. wire to align!

4. The geometry on the pineapple is less crazy. That's purely on the modeling side and has nothing to do with printing it, but it makes me happy.

I've also added some variety on the parts. There are 2 different sized pineapples, 2 different size mace heads, and 2 different spikes. You can mix and match whichever ones you like.

I've also got a mix of larger parts for printers with more Z height, and smaller parts for printers that can't do a 12" tall part.

Since this is going to get banged around a bit (assuming you are costuming with it!), I recommend printing it using wood filament with 4x perimeters, 4x tops and 4x bottoms. For the pineapple you really want the spike pretty solid. I did 45% infill there. You could probably do less, or use different settings for different heights. I like having the weight there.

Same for the mace. Doing 4 perimeters makes the blades and tip of the spike pretty darned solid. I use black for this one.

For assembling the totokia you need:

• 1 x end (either long or short)

• 1 x bend transition

• 1 x bend

• 1 x pineapple (large or small)

• 1 x 1" wooden dowel

The number of segments you use is up to you -- you can make the stick longer or shorter as needed. I used 1 x end long and 2 x segment long for my own.

You will need to cut the dowel to length depending on what you printed. You'll also need a small section of dowel for attaching the pineapple to the rest of the club.

The mace is a bit less complex.

• 1 x mace shaft

• 1 x mace head (large or small)

• 1 x spike (large or small)

• 1 1/2" dowel

Same deal, print it, cut the dowel to length. The dowel should be flush with the end of the shaft. I recommend inserting the spike first so that you don't push the dowel up too far.

For finishing it all:

• Sand it smooth. Don't use any filler/primer on the wood part.

• I use wood stain on the totokia, followed by polyurethane.

• The mace I sand/fill/prime until really smooth

• Weld marks on the blades are added with hot glue

• Paint it all metallic silver

• Weather as desired.