Foam Board Weapon Tutorial by FireLilyCosplay

Foam Board Weapon Tutorial by FireLilyCosplay

As a Thank You to all my supporters, here is the Foam Board Weapon Tutorial!

I've had a lot of practice with this method, and this is the formula that works best for me, so I hope it can help you make your props with ease. I really enjoy working with my hands and making props using various methods, so please don't hesitate to ask questions if you have any - I'll be glad to answer them!

Tutorial and all images therein are Copyright Fire Lily and FireLilyCosplay.com.

kat1004 Featured By Owner Mar 19, 2017 Hobbyist Digital Artist

I'm going to use this information for making Kremvh's Tooth from Fallout 4.

This info is very helpful

b-panda1 Featured By Owner Oct 30, 2016 Hobbyist Digital Artist

Hello! ^^ I'm making a prop of Rose Quartz sword. I plan on making it with foam board and a wooden dowel, to support the base of the sword. Do you think that foam board and wood would bond perfectly with contact cement? ^^

Oh and nicely made sword prop and tutorial you provided. ^^

FireLilyCosplay Featured By Owner Nov 7, 2016 Hobbyist Artisan Crafter

I can't say "perfectly," but contact cement should work fine.

narutogoldylocks Featured By Owner Mar 25, 2016 Hobbyist General Artist

This is a great tutorial! Thanks

AnimeRocckr Featured By Owner Dec 24, 2015

Can you please tell me the names of the primer & sealer u used

AruoraOkami Featured By Owner Sep 13, 2015 Hobbyist General Artist

About how durable are the foam board swords? I am planning to use the sword I will make in RP fights. I was also told craft foam works for weapon props if the base layer is industrial tinfoil and then the C foam on top. Opinions? I already made my sword's prototype out of cardboard and the shield that goes with.

FireLilyCosplay Featured By Owner Sep 15, 2015 Hobbyist Artisan Crafter

They aren't meant to be used for actual or play fighting. They are props.

krose502 Featured By Owner Jul 5, 2015

I plan on layering the foam board and making a Final Fantasy Crisis Core Buster Breaker.

Apohermion Featured By Owner Edited Jun 26, 2015

Just curious, where did you get the styrofoam cutter? I've been using a utility knife, but it's not exactly the best for cutting intricate details into the foam board. I've tried searching online, but I get results for electric or hot knives for cutting foam and I'd rather not break my bank buying a tool for it :/

Thanks in advance!

FireLilyCosplay Featured By Owner Jun 26, 2015 Hobbyist Artisan Crafter

I got mine at Michael's Craft store, but I'm sure they're also at Hobby Lobby and elsewhere. Called the Styro Wonder Foam Cutter.

Apohermion Featured By Owner Jun 27, 2015

Awesome. Thank you again! I'll have to keep an eye out for it.

kimhaneuls2 Featured By Owner Mar 9, 2015

to make a pretty big bow. how big do i need the foam board?

FireLilyCosplay Featured By Owner Mar 9, 2015 Hobbyist Artisan Crafter

I don't know - you'll need to figure out your measurements for the size of the bow and calculate how much foamboard you need

kuro-bunny Featured By Owner Feb 28, 2015 Student General Artist

_{What was the thickness of the foamboard you used?}

FireLilyCosplay Featured By Owner Feb 28, 2015 Hobbyist Artisan Crafter

1/4 inch.

Kateorin Featured By Owner Jan 27, 2015

Where do you buy your foam board?

FireLilyCosplay Featured By Owner Jan 29, 2015 Hobbyist Artisan Crafter

At the local craft store.

ILuvAnimeSK Featured By Owner Sep 9, 2014 Student Traditional Artist

Um, how much was this total?

FireLilyCosplay Featured By Owner Sep 17, 2014 Hobbyist Artisan Crafter

How much was what...the sword? The foam board is about $2 a sheet - one sheet for 3 layers. I already have a stock of Gesso, spackle, and sealant. Paint is about $5 a can. Cabochons were $6 for a dozen on EBay.

Time wise? It took about a week total, working on it after I got home from a full time job and two solid days on the weekend.

ILuvAnimeSK Featured By Owner Sep 18, 2014 Student Traditional Artist

Thanks a lot! Sorry I didn't specify...

12starlings Featured By Owner Aug 2, 2014 Student General Artist

Will I have any issues with pieces scraping against each other, or the blades being covered in blood? I'm trying to make a giant pair of scissors. <:3 Thanks

FireLilyCosplay Featured By Owner Aug 8, 2014 Hobbyist Artisan Crafter

You may lose some of the paint unless you seal it multiple times, but it shouldn't be too problematic.

12starlings Featured By Owner Aug 9, 2014 Student General Artist

Alright thank you!

AlleycatIrony Featured By Owner Jun 15, 2014 Hobbyist General Artist

Thanks! I think I might use this to make Karkat Vantas' Sickle~

HP-Jack Featured By Owner May 1, 2014 Student Digital Artist

also would you suggest using the styrofoam cutter form when cutting out the base of the prop or? Because I don't really need to cut anything else out from my prop besides from it's normal shape/outline/base.

FireLilyCosplay Featured By Owner May 6, 2014 Hobbyist Artisan Crafter

The styrofoam cutter will only cut the foam and not the cardboard. You can get long pieces of pink insulation foam for longer props, but you would need a center support or it'll break.

HP-Jack Featured By Owner Apr 30, 2014 Student Digital Artist

I have a quick question, I'm going to start working on a prop soon for an up coming con, but the length of the foam board isn't long enough for how I want the weapon to be. So should I use the contact cement to connect the different pieces of the prop together or?

hentaiboy77 Featured By Owner Mar 27, 2014

I just have a doubt....is it too fragile!? or Gesso make it strongh enough!?

FireLilyCosplay Featured By Owner Mar 28, 2014 Hobbyist Artisan Crafter

Just use something else if you are doubtful. Like fiberglass or epoxy or resin. This is simply one method.

Zakiax Featured By Owner Mar 15, 2014 Hobbyist General Artist

Thank you for this Tutorial it has really helped me.

FireLilyCosplay Featured By Owner Mar 21, 2014 Hobbyist Artisan Crafter

Very welcome!

ImTheNightHerSelf Featured By Owner Feb 28, 2014

Will it stay sturdy and solid if I use paper mache and fast mache? >.<

Ironkau Featured By Owner Feb 2, 2014 Hobbyist Photographer

Does the gesso strengthen the foam board?

Nocturnal--Artist Featured By Owner Dec 10, 2013 Hobbyist General Artist

Could I use mod podge instead of gesso?

tenisgirl808 Featured By Owner Jun 16, 2016

I have used mod pod as a replacement as well but found that if used on foam and exposed to heat it can start to bubble.

FireLilyCosplay Featured By Owner Dec 22, 2013 Hobbyist Artisan Crafter

I don't see why not. It may not have the best affect as it is more of a glue and doesn't sand as smooth as Gesso does.

PapersEdge Featured By Owner Nov 18, 2013

I was just wondering about the strength of the handle.I'm in the middle of making my friend the Buster Sword, and I wanted to use foam board for it along with your method. However, the Buster Sword is notorious for it's huge blade and relatively small handle. Any thoughts?

akadragon1111 Featured By Owner Feb 25, 2014

Use expanding foam for the blade and for the handle a pcp pipe. then coat in wonderflex. Dont try any huge monster hunter swords with foam board it gets way to heavy. expanding foam is the better way to go.

FireLilyCosplay Featured By Owner Nov 20, 2013 Hobbyist Artisan Crafter

Use insulation foam instead and have a wooden dowel inserted for the handle/support.

Antilogist Featured By Owner Aug 26, 2013 Student General Artist

This is perfect! I was trying to make a pair of sickles out of cardboard and model magic, this already seems like a sturdier, easier method! Thanks!

BARCosplays Featured By Owner Aug 4, 2013

So how much will this set me back? If possible, could you give it in terms of per square inch of prop?

FireLilyCosplay Featured By Owner Aug 4, 2013 Hobbyist Artisan Crafter

I have no idea. Foam board is $2.99 for a 20"x30"x.25" board where I'm at. Glue, contact cement, gesso, primer, paint, clear coat, decorations, etc will all be relative to your area.

Maybe you could go price it on your own so you have a better idea

BARCosplays Featured By Owner Aug 5, 2013

Well, I was thinking in terms of Michael's and JoAnn's in the DC area. But I'm going to do the investigation today.

Puddle193 Featured By Owner Jul 28, 2013

This may seem like a stupid question but what kind of of foam board do you use all i can find is like 1/8 inch thick or 8ft by 4 ft installation foam and thats horrible to store. oh also where do you get it?

FireLilyCosplay Featured By Owner Jul 28, 2013 Hobbyist Artisan Crafter

I get mine at Michael's craft store. They have 1/4 inch and 1/2 inch. Usually around the art section on the kid school project section.

Puddle193 Featured By Owner Jul 30, 2013

Thank you so much, I just made a bunch of Soul eater props and I had to buy a huge sheet of installation foam and I was a pain to get home from the store.