How to Make a Foam Board Sword

Styrofoam is commonly used in manufacturing as a packing product, but it can also be used for scenery in theater, as stage props, and also for toys. Foam swords are a popular item for children because of the safety factor. Foam swords can be purchased at most toy or prop stores, but there is no need to purchase one at a store when you can very easily create one at home.

Difficulty: Moderate

Instructions

Things You'll Need:

• 2 by 8 foot foam board 2 saw horses Marker Small electric chain saw Japanese hand saw Power sander Clear acrylic spray paint

1. Find a well ventilated room to work in. It is ideal to work outdoors as fumes from the Styrofoam can make you sick.

2. Set up 2 saw horses. The saw horses make it easy to work around the foam. If you don't have a saw horse, any flat surface will do.

3. Lay the foam across the saw horses. Use the marker to draw the outline of the sword. If you aren't good at freehand drawing, find a large sword stencil. You can also print out sections of a large sword, cut out the center, and then tape them together to create the stencil.

4. Use the electric chainsaw to cut out the sword. Use the japanese saw to fine tune the edges. You can also use it to define small details.

5. Smooth the edges with an electric sander. Go slowly to avoid damaging the foam. Paint if desired and seal with acrylic spray.

Tips & Warnings

• Wear safety goggles to avoid flying pieces of foam getting in your eyes.
• Cutting to quickly can result in cracking. As the foam melts during sanding, it will put off fumes making it important to work in a well ventilated area.

Resources

• How to shape foam