EVA Foam Cosplay Sword Tutorial (She-Ra)

  • By: NickG
  • Date: August 23, 2021
  • Time to read: 9 min.

How to make swords out of EVA foam

The pattern set for this costume is available here : https://kinpatsucosplay.com/product/she-ra-cosplay-patterns-pdf/

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Everyone it’s competitive cosplay here and today I’m gonna be showing you guys how to make an Eevee a foam sword using this Shearer sword as an example if you guys would like to see more cool cosplay tutorials like this one check out our website where we have tons of great tutorials and resources for cosplay so to build my Shiro sword I’m gonna need my template which I’ve printed out onto some paper and cut out I’m then gonna

Need a wooden stick or dowel to go through the center of the sword to add stability and I’m gonna use some 2 centimeters thick high-density EBA foe I’m taking my pattern and tracing around it onto some 2 centimeter thick EBA phone I’m tracing around my sword twice so that I have two halves of my sword to cut the pieces out I’m taking a nice sharp craft knife and a ruler and carefully cutting the pieces out make sure your knife is nice and sharp so

That it doesn’t rip the pieces of foam and you get nice clean cuts the piece of foam I had wasn’t quite big enough for my whole sword pattern to fit onto it so I had to cut extra handle section which I’m going to glue into place so the idea now is that we’re gonna take our two pieces of foam and sandwich the stick in between the two pieces to add extra strength and stability I’m drawing a line down the center of one of my pieces of foam then using my craft knife I’m

Gonna cut the channel into the center of the foam which the stick is going to sit inside of to cut my channel I’m just taking my craft knife and cutting out a 45-degree angle which is making a nice V channel all the way through the sword just don’t cut too deep because you don’t want the cuts to come out the other side of the sword now that my channel is deep enough I’m gonna take my dowel stick and I’m gonna take some contact glue and glue it into place

Instance I’m then gonna repeat this process on the second half of my sword cutting another channel for the other half of the dowel stick to fit into so that when we sandwich the two pieces of foam together they lie nice and flat and the stick is inside now we need to glue the two halves of the sword together so to do this I’m using contact glue how contact glue works is you need to put glue on the one surface glue on the

Other surface let them get a little bit tacky and then you can press them together and it forms a really strong bond so I’m taking my tube of contact glue and I’m gonna be putting it all over the one half of the sword this takes a really long time and you can help spread out the glue with extra pieces of foam once I’ve covered both halves of my sword in glue I then need to speed up the drying process just a little bit so

I’m taking my heat gun and gently going over the glue until it’s tacky now that the glue is nice and tacky and sticky I’m gonna press the two halves of my sword together so I’m gonna line them up nice and carefully along the edges to try and get them as even as possible and then I’m gonna press the two halves together now unless you are a laser cutter your pieces are probably not going to line up completely perfectly and you’re gonna have some uneven edges

So to fix this I’m just gonna take my craft knife now and cut off any excess where the pieces have not lined up properly the base of our sword is now complete so we can start adding on some details so to do this I’m taking my pattern and I’m gonna be tracing around pieces of it to draw on where I want my details to go on the sword all the details on this sword are gonna be carved into the foam itself so there’s no additional pieces that we’re sticking

On so I’m taking a small craft knife and slowly and carefully carving into the foam itself and cutting away pieces to create bevels and shapes in the phone once again I suggest using a really really sharp knife or sharpening your knife throughout this process so that the cuts are as clean as possible but if the cuts are not perfect and not as as you want them don’t worry because I’m gonna show you how to fix this and clean it up even more now I’m also gonna use

My knife to carve out the basic shape of the bevels on my sword this is gonna look really really rough with a cross knife because they’re so small and you can’t get those nice big smooth cuts on the bevels but I’m gonna show you how we can smooth this out in just a second so to smooth out the surface of the sword I’m going to be using a hand sander a hand sander is a really great tool if you’re working with larger surfaces I normally use a rotary tool

For the smaller details on my weapons but for big surfaces like the edge of a sword the hand sander is the best because it will give you the smoothest finish I’m moving this hand sander in a circular motion or back and forth over the rough edges this is gonna take a little bit of time to get it smooth but just keep working over the surfaces until it’s as smooth as you want it when sanding EBA foam I suggest using a dust mask and some goggles when sanding the

Foam the dust is going to go absolutely everywhere and make a huge mess so you don’t want it in your eyes and up your nose for the smaller details where it’s a little bit too hard to get in with a hand sander you can use a rotary tool or a dremel to go in and refine those smaller more delicate areas now the sword is nice and smooth and polished to help get off any other fluffy pieces that may have come from the rotary tool and the hand sander I’m then using my

Heat gun and going over the surface burning off any of those tiny pieces of foam there may be some spots where you cut off a little bit too much foam or some strange seams that are not totally lining up properly to help fill in the seams and fill in any gaps that you want to fix you can use foam clay I’m using foam clay from lumines workshop I’m taking a little bit of the foam clay and putting it onto my seam then I’m taking

Some water and using my fingers I’m smoothing out the clay over the surface when this dries the seam will be nice and hidden I’m also gonna be using some more foam clay to sculpt the pummel at the end of my sword so I’m just taking a big bowl and starting to roll it out on the table and refine the shape and then going to let it dry and once it’s completely dried I’m gonna put it on top of my sword when foam clay dries it acts exactly like a VA foam which is really

Really awesome and can be used in a variety of cool ways now that the sword is built it needs to be primed and prepped for paint the one problem with EBA foam is that it looks like foam it looks like a sponge so we have to prep the surface and make it nice and smooth and shiny so that it looks like plastic or metal to get my surface nice and smooth I like to use PVA wood glue the wood view I use is called cold glue and it’s really great because it makes nice

Thick layers and by the end of it it looks like a nice smooth plastic finish so I’ve poured some of my wood glue into a cup next to me and then I’m taking my brush and a little bit of water and I’m spreading the glue all over the surface of the sword don’t put too much on at a time because if there’s too much glue it can create runs and drips and you don’t want that you want a nice smooth surface so I’m gonna paint on my first layer of wood glue and let it dry completely when

It’s dry it will go back to its original color and it won’t be white anymore I’m then going to repeat this step six times so that I have six layers of wood glue and the surface is nice and smooth and beautiful this is what it’ll look like when all the layers of wood glue are on to get an even smoother finish on the wood glue you can even wet sand it so to do this I take some sandpaper and I dip it into the water and then in a circular motion

I go all over the wood glue you can also paint some water onto the wood glue and then sand over that this will get rid of any other tiny bumps on the surface and make the wood glue nice and slick and shiny now that my sword is completely primed with wood glue I’m gonna put one layer of rest oleum grey primer onto the sword to prep it for paint I’m going to start by painting the gold of my hilt so to prevent the gold paint from going onto the sword I’m gonna be taking some

Masking tape and masking off that section to protect it from my airbrush so I’ve mixed up some gold paint in my in water airbrush and I’m gonna be spraying it all over the hilt of the sword you may need to spray a couple of layers to get the color you want I really love painting with airbrush because it gives you a beautiful smooth finish but you can also paint this by hand with some acrylic paints once I finished painting the gold I let it dry

Completely and then I mask off the gold section so that I can paint the blue section of the sword once again I’ve mixed up my airbrush color and I’m just slowly and carefully spraying on my layers until I get the color I want you can then remove all the tape to reveal your final paintwork for the final details on this sword I used a silver sharpie to draw on the markings and I also used a clear acrylic egg

Which I got from a crafting store and I painted the inside with some blue nail polish this same building technique can be used for a whole range of different swords and weapons and that’s how I made this really awesome sheera sword thank you guys so much for watching and if you enjoyed this video please like it and also subscribe to our YouTube channel bye guys

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