On the 3D printing: my only word of caution for buying from shapeways is to make sure you have a buttload of sandpaper on hand. I'd definitely resin coat the outside and then sand the ever loving crap out of it to get rid of the low resolution stepping. Other than that, sounds like a solid plan. I like the design you came up with for it, although I'd watch the topmost angle for breaking. Maybe connect the bottom of the axe head to the handle with a thin strip of material, so there's still the cutout but a bit less torsional flexing. Dat pipe... love it.
Thanks for the advice, I should really go buy some sandpaper, I keep using all my room mates I figured I would need to add some sort of wooden or metal rod into the shaft to strengthen it, especially where the handle meets the head. I guess stuffing a glob of epoxy sculpt down its neck would be a good plan too, to strengthen the bend. Boshwan has graciously offered me a chance to use his 3D printer for the axe, which is fantastic! It would be much less cleanup and probably stronger than Shapeways would print it (and a butt load cheaper). It'll be a few weeks before I get it, but I'm in no rush on that part. I'll also be writing an Instructables about it, and it'll get its own thread in the props section.
Hey, how much would I have to pay for you to make me a full erebor dwarf armor foam suit?
Is the pepakura file out? I tried going into the one you put up, but it brought me to a dropbox site error screen. Do you think you could send me the file? I'm really interested in trying this. Nice work by the way!