How to Make a Flail

Last Updated: November 22, 2022

This is a complete tutorial with lots of pictures and a video that will show you how to make an ornamental medieval flail. A flail is a kind of mace with either a string or chain attaching the ball to the handle.

Steps

1
Wrap some newspaper in a ball. Don't make it too tight as the tighter it is, the heavier it gets, and a heavy mace ball is dangerous.
2
Crunch it up loosely then wrap some masking tape around it.

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3
Wrap the string around the head of the Mace.
4
Wrap your string around the mace ball. Wrap it in different spots and wrap at least 4 times. With a varied wrap like this, the ball will not come off the string. Tie a knot after each wrap.
5
Attach the chain. If you are using plastic chain, thread each wrap of the string through the link as shown. Every wrap should go through the chain. This is both for strength and for safety. If you are not using a chain, then create a hoop with these string lengths. This way you can run another series of strings through it and attach them to the handle of the flail.
6
Tape the whole ball of the mace. Complete the shape and size of the ball head by taping it over completely. Don't be stingy with the tape; the more tape you use, the stronger it will be. Make it as reasonably smooth as you can and shape it as much like a ball as you can. You will be painting this surface, so the smoother the better.
7
Make the cones. The pointy cones will attach to the mace ball.
- Cut a circle.
- Fold the circle in half.
- Curl the half circle forming a cone.
- Make 8 to 16 cones depending on the size of the flail.
8
Attach the cones to the head of the flail. Tape the cones to the head of the flail. Use a nice random pattern and tape them down nice and secure so they don't come off. do not fill them with newspaper. We do not want them to be overly strong. It is better that the collapse or get crushed rather than cause damage or injury to someone.
9
Prepare the handle. Drill a hole in the end of the flail handle as shown. [Picture required] (Through the side at around half inch from the end. This is for strength and safety.
- Pass the string through it several times and with each pass put it through the chain. If you are not using a chain, then just make each pass into a loop. Tie several lengths of string to this loop and about 15 to 18 inches (38.1 to 45.7 cm) further along, you tie all the strings to the loop in the mace ball.
10
Finish up. The flail is complete and ready to be painted.

Community Q&A

Question

How do I get the string tied to the chain?

Community Answer

A flail is one piece. Separate pieces are attached during the making of it.
Question

What adhesive do I use to attach the spikes to the ball?

Gus B

Community Answer

It would be a good idea to use hot glue, but if you don't have a hot glue gun, I would recommend super-gluing them, then smearing a bit of school glue around the edges.

Warnings

An important note about the safety of this flail: Safety is the most important thing you should think about when making and using this flail. The string and or plastic chain should be very strongly secured to both the handle and the ball of the flail. You absolutely have to make sure the mace ball will not fly off if you swing this flail. And you must never use this flail against another person. The sharp points can be dangerous to peoples eyes, and this includes your own eyes. It would be very easy to swing this flail and hit yourself in the face. This is an ornamental flail to be used only as a costume accessory.

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