![]() It’s a bit over 1” in diameter, which is perfect. We used a cardboard core from shipping labels for the sword grip. Use more layers of foam to create a thicker block and use the plastic to stabilize if necessary. Repeat steps one through four to create the cross-guard, hilt and pommel. Let dry between coats, sand out any imperfections as needed and add extra layers of sealer to smooth them out. Use a water-based sealer and cover the entire surface of the foam blade several times until all surfaces are smooth. ![]() This is the fun part - add as many scuffs as you can think of battle stories for, perhaps, a gouge made by a dragon tooth? Step Four: We Have Many Tools Perfect for Cosplay - Check ’Em Out! We cut the scuffs with a utility blade, made the round holes with a burnishing tool by puncturing the foam and added the scratches with an awl. We also added a few battle scuffs and nicks during this step to give the blade a battle-used look. You can even out the rough parts with sandpaper or a sandstick and hide the rest with coats of water-based sealant later. You can use a number of tools to do this, including a utility knife or an electric sanding tool. ![]() Visit Our Shop for All Replacement Bladesīevel the edges of the blade. This will create a groove in the foam to use as a guideline when cutting.Ĭut the blade shape out from the foam using a snap blade utility knife or a craft knife and make sure the blades are fresh and sharp. Tool Tip : Use a ruler to draw all the straight parts and press the pencil into the foam. Use more layers of foam if your cosplay sword calls for it.ĭraw the outline of your sword blade with a pencil. Pieces should be longer and wider than the design calls for. First, rough cut two pieces of foam for the blade part of the sword. Step One:ĭetermine the length of the sword you’ll be making for your cosplay costume. Have all your materials and tools ready and protect your tabletop by working on a cutting mat - especially when cutting.
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