A quick step by step of how I made Hornet's Needle.
Template available here if you want to build along.
Materials:
1/2 inch EVA foam
1/2 inch PVC pipe (I use sch. 20 because of the thinner wall thickness and smaller diameter)
1/8 inch Sintra (this material is optional)
1/2 inch EVA foam dowel
Plasti Dip (Spray can, black)
Acrylic paint in silver (I uses spray paint but you can brush paint if you prefer)
A clear coat of choice
Sandpaper in various grits from 120 to 800
First I used my template to cut out two blade sections from EVA foam and one from Sintra. Then I cut channels out of the foam and a slot out of the Sintra to fit the PVC pipe.
Note: If you plan on taking your Needle to a convention do not add the Sintra core. Most weapons policies consider it a hard edge and not con legal.
Next I glued all the pieces together.
Then I started shaping. I used a blade to cut away most of the material at the edges and blended it all out with my lowest grit sandpaper. This process takes a lot of time and patients. At times it will feel like you are not making any progress but stick with it.
Alternatively you could bevel the inside of your foam pieces before gluing them together. But this will give a flatter look to the prop overall. If you want the same long, gradual angle I did, sanding is your best bet. Also if you are using the Sintra core you will have to do some sanding regardless.
Once I achieved the shape I wanted I started working my way through the higher grits of sandpaper. This smooths out the foam and ensures a nice smooth and even finish when you paint.
Once all the sanding steps were finally fished I glued a piece of foam dowel into a ring and gave it a little tale (another little piece of foam dowel) and glued it into the end of the pipe.
With all the build work done I heat sealed all the foam and started the paint process.
First was a few thin coats of Plasti Dip. Then a last, thicker coat. I find this gives me the smoothest finish. I used black because silver looks the best when it's over a black base coat. I don't know the science behind that I just know it works.
After the Plasti Dip dried completely (48 hours) I applied my silver paint. Like I mentioned before I used a spray paint but you can paint with a brush or airbrush if you prefer.
Note: Always be sure to use acrylics when painting foam, enamel paints will crack when the foam flexes.
The last step is to apply a clear coat. Be sure to let your paint completely dry first. You can use whatever brand and finish you prefer. I'd recommend a gloss but it really is personal preference.
Kofi