How to make a cosplay axe?

Introduction

Materials and Tools

• EVA foam (various thicknesses: 2mm, 5mm, 10mm)
• PVC pipe (3/4 inch diameter, approximately 30 inches long)
• PVC coupling (3/4 inch)
• Contact cement
• Craft foam
• Plastidip
• Acrylic paints
• Clear coat
• Caulk
• Bamboo skewer or wooden dowel
• Leather or fabric strips (for handle wrapping)

• Craft knife or box cutter
• Scissors
• Heat gun
• Dremel or rotary tool
• Sandpaper (various grits)
• Cutting mat
• Ruler and measuring tape
• Pencil or marker
• Paintbrushes
• Hot glue gun
• Printer (for templates)

Step 1: Design and Planning

1. Research and gather reference images of the axe you want to create. Look for multiple angles to understand the overall shape and details.

2. Create or download a template for your axe head. You can find templates online or design your own using image editing software.

3. Print out the template and cut it out. If it's larger than your printer paper, you may need to print it in sections and tape them together.

Step 2: Creating the Axe Handle

1. Cut your PVC pipe to the desired length (usually around 30 inches for a full-sized axe).

2. If you want to add a curve to your handle, use a heat gun to carefully warm sections of the PVC pipe. Once it becomes pliable, gently bend it to the desired shape. Be careful not to overheat or burn the PVC.

3. Sand the entire surface of the PVC pipe to help the foam and adhesive stick better.

4. Cut a strip of 2mm EVA foam wide enough to wrap around the PVC pipe. Apply contact cement to both the foam and the pipe, let it dry for a few minutes, then carefully wrap the foam around the pipe, smoothing out any bubbles or wrinkles.

5. For added grip and detail, you can wrap additional layers of foam or craft foam around certain sections of the handle.

Step 3: Crafting the Axe Head

1. Trace your template onto the EVA foam. For a basic axe head, you'll need two identical side pieces (use 10mm foam) and a center piece (use 5mm foam).

2. Cut out the foam pieces carefully using a sharp craft knife or box cutter. Take your time to ensure clean, precise cuts.

3. Use your Dremel or rotary tool to bevel the edges of the axe blade. This will give it a more realistic, sharp appearance.

4. Heat the beveled edges with your heat gun to seal the foam and create a smoother surface.

5. If your axe design has any additional details or layers, cut these out of thinner foam (2mm or 5mm) and prepare them for assembly.

Step 4: Assembling the Axe Head

1. Apply contact cement to the edges of your center piece and the inside faces of the side pieces. Allow the adhesive to become tacky.

2. Carefully align and press the pieces together, ensuring they're properly positioned before the adhesive sets.

3. If your design includes additional details, glue these onto the axe head using contact cement or hot glue, depending on the size and placement of the pieces.

4. Use caulk to fill in any gaps or seams between foam pieces. Smooth it out with your finger or a tool, then allow it to dry completely.

5. Sand any rough areas or excess caulk to create a smooth surface.

Step 5: Attaching the Axe Head to the Handle

1. Cut a small slit in the bottom of your axe head where it will connect to the handle.

2. Insert the PVC coupling into this slit, using contact cement or hot glue to secure it in place.

3. Slide the handle into the coupling, applying adhesive to ensure a strong bond.

4. Use additional foam pieces or craft foam to cover the connection point and create a seamless transition between the head and handle.

Step 6: Adding Details and Textures

1. Use your Dremel or rotary tool to add any additional textures or details to your axe head, such as wood grain patterns or metal rivets.

2. For raised details, cut small pieces of thin foam and glue them onto the axe head.

3. If your design includes leather straps or bindings, cut these from craft foam or actual leather and attach them using contact cement.

4. For a wood-like texture on the handle, you can use a wood burner tool or a heated knife to create grain patterns in the foam.

Step 7: Sealing and Priming

1. Use your heat gun to carefully seal the entire surface of the foam. This closes the pores and creates a smoother painting surface.

2. Apply several thin coats of Plastidip to the entire axe. This creates a durable base for your paint and helps protect the foam. Allow each coat to dry completely before applying the next.

Step 8: Painting

1. Start with a base coat that matches the primary color of your axe. For metal parts, use a dark gray or black; for wooden parts, use a brown shade.

2. Once the base coat is dry, use dry brushing techniques to add depth and highlights. For metal, use silver or gunmetal; for wood, use lighter brown shades.

3. Add any additional colors or details according to your reference images. This might include rust effects, blood splatters, or magical runes.

4. For a realistic metal finish, you can use metallic rub-n-buff or metallic acrylic paints.

5. If your axe design includes leather elements, paint these using appropriate leather-like colors and add highlights and shadows for realism.

Step 9: Weathering and Finishing Touches

1. To make your axe look battle-worn, add weathering effects using dry brushing, washes, or sponge painting techniques.

2. For metal parts, you can create rust effects using orange and brown paints applied with a sponge or stippling brush.

3. Add scratches and dings using silver paint and a fine brush or silver marker.

4. For wooden parts, add darker shades in the recesses and lighter highlights on raised areas to enhance the wood grain effect.

5. Once you're satisfied with the paint job, apply a clear coat to protect your work and add shine if desired.

Step 10: Handle Wrapping (Optional)

1. If you want to add a wrapped handle for better grip and authenticity, use leather strips or fabric.

2. Start at one end of the handle and use hot glue or contact cement to secure the wrapping material.

3. Wrap the material tightly around the handle, overlapping slightly as you go.

4. Secure the end of the wrapping with glue and trim any excess.

Tips for Success

• Take your time with each step, especially cutting and assembling foam pieces. Precision is key to a professional-looking result.
• Always work in a well-ventilated area, especially when using adhesives, Plastidip, or paints.
• Test your paints and techniques on scrap foam before applying them to your axe.
• Consider the character or game your axe is from and add appropriate details or symbols to make it recognizable.
• If you're new to foam crafting, start with a simpler design and work your way up to more complex axes as you gain experience.

Safety Considerations

• Always use proper safety equipment, including eye protection and a dust mask when cutting foam or using power tools.
• Be cautious when using the heat gun, as it can cause burns or melt the foam if held too close for too long.
• Follow all safety guidelines for any tools or materials you're using.
• Remember that your foam axe is a prop and should not be used as a real weapon or swung at others.

Maintenance and Care

• Store it in a cool, dry place away from direct sunlight.
• Avoid placing heavy objects on top of it to prevent warping or damage.
• Touch up paint as needed before events.
• Clean with a soft, dry cloth to remove dust.

Conclusion