Use a water-based sealer to finish the faux leather cord. To keep our fingers clean, we used a burnisher to hold the strips in place. First, we applied a layer of brown and then dabbed the burnt orange and mustard yellow to blend. To recreate the look of distressed leather, we used three colors of paint - brown, burnt orange and mustard yellow. Need the Right Scissors for the Right Project? Check Out Our Shop! Glue as you wrap to keep the faux leather foam in place. The sharp 8” blades allow for a smooth, continuous cut of the EVA material.įor an alternative grip design, cut the pre-painted strip into narrow strips, about 1/8”, and wrap in a neat spiral around the cardboard grip. You’ll need the 1mm thickness foam for this part. To wrap the grip, make a faux leather cord. We chose to paint ours in faux leather to match the faux leather cord we’ll be wrapping the handle in. Paint the foam surface with a seal and then acrylic paint in your choice of color - like metallic silver or gold. Cover the entire surface area of the core with a thin, even layer of glue so that the foam adheres securely. Once you have the core for the grip, you’ll need to cover it. Other materials that you can use for the grip’s core are a wooden dowel or a 1” PVC pipe. You can use paper towel cores by cutting them down the center and layering a few of them so it’s more solid. 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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