What exactly are you trying to make? I mean, for what character/weapon? Do you have a picture? It might help in determining the best materials to use.
I'm trying to make a giant cogwheel out of a hoolahoop, too, for Tira's Joke Weapon from Soul Calibur III. (I'll probably also keep it and use it for a steampunk accessory. xD) I'm thinking cardboard for the pegs and the center bar, and then covering them with something, but I'm not sure what yet.
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