Steps to making your own EVA foam weapons guide.
1. As mentioned in my previous post, I scaled the weapon to size from a projector hooked up to my Xbox 360. After that was done, I cut the weapon out, and placed it against a white sheet of ½ inch EVA foam board *the connect-a-mat kind from Wal-Mart* and traced the pattern out. Twice.
2. Here’s what you’ll come out with. *I made a mistake here, I cut out 2 left-sides, I went back and cut out a right-sided pattern. You’ll need to cut out 2 to make it the proper size AND for what you’ll see next.
3. I then used my rotary tool to wear down the traction/patterned side, *you don’t have to do this* but it helped create a flatter surface for the glue to adhere better.
4. This is perhaps the most important part, ALWAYS have some kind of core for your foam weapons. I made this on sunday and all the stores were closed so I improvised. I used a coat hanger *ashamed* as the core. But I would recommend using some kind of metal rod. One that’s thin enough to bend into the needed shape, like I did with the coat hanger here. You’ll need the core, I skipped this step once and my foam weapon had no hold, I couldn’t swing it and looked terrible.
5. Now with the core in place, I glued the two halves together. It probably won’t align up everywhere. You’ll have edges sticking out further than the other here and there. But don’t worry about that. That’ll get fixed with sanding.
6. Now comes the part, whether you’re making a sword or a dagger, that’ll take the longest. Sanding. I’d recommend using a rotary tool/Dremmel tool with round sanding heads. This will save you LOADS of work. But make sure to buy a face mask/respirator. You’ll have tonnes of foam particals coming off this when you’re sanding, trust me, I know.
7. Depending on what weapon you’re making. You may need to ‘burn’ in designs into the dagger/sword. I had to for this weapon, The Blade of Woe. But if you’re not comfortable working with a hot knife, you could probably just use a regular knife to cut the designs out. But a Hot knife with a sharp pointed *not bladed* edge is what I used here.
8. After adding paint, here’s what it came out looking like in the end. *The hand wrap is actually the elastic band used in sweat pants. Don’t worry, they weren’t used. But you can buy these at any craft or fabric store.
And that’s it. It’s quite simple, just takes a VERY long time. This here took me anywhere between 8 to 10 hours to make. Not continuously, but it did take up most of my weekend to make.
The last pic is my finished blade and how it looks on the one who I made it for. The blade alone was quite good, when paired with it’s in game owner, Astrid, Leader of the Dark Brotherhood, it looks amazing.
***Last pic taken by; timeywimeyhedgehog
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