After seeing Star Wars Episode VII: The Force Awakens, I knew I wanted to build a Kylo Ren costume. I’ve now finished the helmet, but was also concurrently working on a Rey costume for the wife. In the same way I started the Kylo Ren costume with the helmet, I started the Rey costume with a DIY Rey staff.
It looks like there are a few people on The Replica Prop Forum who have made some really good 3D-printed parts to build a DIY Rey staff. However, those parts alone were very expensive – although accurate – and I just didn’t want to shell out so much for the staff alone. So what’s the next-best way to go about this? That’s right! DIY!
A quick Google search for DIY Rey staff takes one to the incredibly-helpful Instructable on how to build your own using parts from Home Depot for about $40. I highly suggest you check it out. I used it as a guide to build my own staff, but didn’t do it 100% the same because I either couldn’t find or didn’t have the same materials.
Obviously, this all started out by gathering materials. Here’s what I picked up from Home Depot:
- 2 super-cheap white plastic showerheads
- 1/2″ plastic conduit (so it’s lighter)
- 2 Southwire 1/2″ Liquidtite connectors
- 4 clear acrylic sink handles
I had the rest of the items I needed at home, including the wire for the handle details, some nice linen pants that are now rags, random pieces of leather and foam, and plasti-dip.
- 12-gauge wire (from the electrical panel install)
- A thick wire (cord) for the end of the handles – I used an old computer power cable just like the Instructable said
- Phone cord
- Small scrap pieces of EVA foam
- A can of black plasti-dip.
- Spray paint (of course I have tons)
- Respirator mask
- Leather scrap from the Captain America gloves
- Linen scraps from some pants I found at ARC for $4.99 for the wrap
- Cheap strap-like belt from ARC
- Buckles (leftovers from the Cap costume build)
Then, following the Instructable linked above, I just put it all together! It all worked fairly well, although I had to do a little bit of problem-solving to make sure things looked good. For instance, those 1/2″ Southwire connectors didn’t go on as perfectly as I’d want, so I filled them with some EVA foam so that there wasn’t a big gap.
And wrapping that thick 12-gauge wire was not as easy as I’d hoped! It really didn’t want to stay put, so I had to glue it down every few wraps. By the time I was done with both handles, my hands were pretty tired.
One thing I do wish I’d done is either used thicker conduit or put a dowel or something on the inside to prevent it from bending. Sure, without anything else inside it, it’s nice and light for our Rey model to carry around, but it kind of “bounces” and sags at both ends. It’s definitely not a problem when it’s on display, but has the potential to look funny in pictures if we’re not cognizant of it. Anyway, take a look – here’s it drying:
After the initial assembly and coats of paint, I added the linen cloth wrap. For that, I used these nice and cheap linen pants I found at ARC and cut the fabric up into strips. Then I just coated them with a light coat of black spray paint (for weathering) and wrapped them around the staff! I also wrapped some random leather pieces I had to give it that look of “hey this was made by a scavenger”.
Then I cut out the correct shape and size from the leather scraps I had on-hand, and hammered in the snaps and attached the buckles.
I wrapped and snapped those onto the staff, attached the strap and a couple buckles, and it’s all done!! Total cost – about $50. Here’s the finished DIY Rey Staff:
Not bad, eh?