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Step 5: Foam Clay

Picture of Foam Clay

So a new product came onto the Cosplay scene last year that being Foam Clay! This air dry material, which resembles EVA foam once cured, can be easily applied and sanded to it's desired shape once it has hardened (approx 24 hours depending on thickness). I figured that this would be a great material to use to create the complex curve in the middle of the weapon. Water was placed onto the HD-Foam (this helps the clay stick better) and Foam Clay was applied by hand and then smoothed out using tongue depressors that had been dipped in water. This section was allowed to dry for a day and a half before being sanded to the final shape. While this part dried I worked on a circle jig and the handle.

If you want to check out Foam Clay it is available at