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Make your own foam battle

axe
You will need:
Pattern: at the end of this PDF. When you print it, measure against the print guides to know the
scale is correct. ** when printing, make sure scale is set to ACTUAL SIZE**
Ballpoint Pen
Scissors
Ruler
Cutting Surface: Somewhere to cut where you wont be destroying anything.
12mm EVA Foam: I used the interlocking foam mats that you can find almost anywhere, they are
often used for gym floors or as anti fatigue mats.
One sheet of 2 mm EVA craft foam: I used a large sheet, dimensions 30.4cm x 45.7cm or 12x18
inches.
Very Sharp Knife: If it is not really sharp you will have a terrible time when you are cutting the
foam. I use a surgical scalpel.
Electric carving knife: This is not essential, but makes a really nice smooth cut. You can use a
really sharp knife instead.
1/2 inch PVC electrical conduit: I used a 60 cm length.
Saw: Something to cut the conduit. Almost any kind of saw will work.
Hot Glue Gun: I find that I like to use the small ones, because you dont want a lot of extra glue
squeezing out of the seams, and it is easier to control with a smaller tip.
Sandpaper: Some coarse sandpaper around 80 grit, to help smooth any jagged cut lines.

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 Paint: The best is artists acrylic paint, but I have also used ordinary house paint as well. I used
Grumbacher Academy Mars Black, and Grumbacher Academy Burnt Umber
Rubber Gloves: Used for applying the metallic paste.
Metallic Wax Paste: In the past I have used Rub N Buff, but in this project I used DecoArt
Metallic Lustre Silver Spark(affiliate link). I actually prefer the DecoArt, but either will work
fine.
If you are looking for a place to source Rub N Buff metallic wax paste, the best deal I found was here
http://www.allartsupplies.com, I bought about 5 tubes from them and was happy with their service.
The DecoArt Metallic Lustre I bought at Michaels, however, I have since gone back to buy more and they
appear to not stock it anymore.

If you havent already, please refer to my video at https://youtu.be/ra3QSbxprTQ

Step 1: Print the Pattern

You will need to print the pattern page of this PDF. Make sure the scale is set to actual size. Measure the
print guides with a ruler to verify that they are the correct size.

Step 2: Tracing Your Pattern

Place the paper pattern pieces on the foam, and trace around them with the ballpoint pen, holding them
firmly so that they dont move while being traced. Many pieces need to be traced more than once, which is
indicated on each pattern piece.

On the 12mm foam: Trace piece #1 twice.

Trace piece #2 four times- Two with the pattern right side up and two with it flipped
over.

Trace piece#3 twice.

On the 2mm craft foam:Trace pattern piece #4 four times, twice with the pattern flipped over.

Cut two strips 3cm wide and 45 cm long

Step 3: Sanding
Some foam mats have a textured surface that has been formed through heating the foam. This closes off the
cells of the foam and makes it so the hot glue doesnt adhere very well. I like to quickly sand the surfaces that
are going to be bonded before glueing to make sure of a good bond.

Step 4: Start Glueing

Glue the two piece #1s together.
Glue two halves of piece #2 together. Start on one section of the piece, hold it until the glue cools, then open
up the two halves as far as you can and glue the next section, until you have glued the two halves completely
together. Repeat with the other set of piece #2s.
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Step 5: Cut the Bevel
This is where the electric carving knife comes in handy. Cut at an angle all the way along the front edge of
the axe blade to give it a bevel.
You can also use the carving knife to cut a 45 degree bevel on the edges of piece #3.

Step 6: Assemble the Axe Head

Glue along the back edge of one of the blades and line up one of the rectangular pieces and place it on top.
Then glue the other side. If you have lined up the blades and the rectangular piece properly, there should be
enough space for the piece of conduit between the blades.

Cut the 1/2 inch PVC electrical conduit into a 60cm (2 ft) length.
Now put lots of glue in the cavity that the PVC pipe will go into and place it in position.

Now apply glue along the remaining side of the PVC Pipe and press the other rectangular piece into
position. Once that glue has cooled, Glue the edges of the rectangular piece to the edges of the blade
sections.

Step 7: The Handle

Give the handle a quick sand down to help the glue and paint stick to it properly.
Take one of the 3cm x 45cm strips and glue it to the handle in a diagonal so it winds up the handle with
about a 1.5 cm gap between the strips. Glue the strip to the handle as you go. When you get to the end of the
strip, cut it off perpendicular to the handle.
Cut the other strip in half, and wrap half around the bottom of the handle, and use the other half at the top.
You dont need to use the full half strip, just go until it is as thick as you want it.

Step 8: Paint
Paint the axe black- I strongly recommend a minimum of two coats of a good quality artists acrylic paint,
maybe three. This will give you the best surface to apply the metallic past to.

Paint the handle with the burnt umber acrylic paint.

Step 9: Make it look kinda like metal

Put on a rubber glove.

Take a little of the metallic paste and spread it on a sheet of cardboard with your finger, trying to get just a
very thin layer on your finger, then apply the paste to the painted surface of the axe in a circular rubbing
motion. It can take some practice to get the look you want, but if it isnt looking great, you can always paint
black over top of the metallic paste and start again.
I like to give a coat of ModPodge over the paint at the end to keep the metallic paste from rubbing off.

Step 10: Youre Done!

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I would like to sincerely thank you for purchasing this pattern, I would love to see what you
create with it. If you would like to email me photos, please send them to:
lostwaxoz@gmail.com

Also I am always looking to improve your experience, so if you have any problems or
suggestions, I would love to hear them as well!

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 2
Cut 2
4 Cut 4 (2 with pattern flipped)
Cut 4
(2 with pattern
flipped)
3

1 Inch
1
5 cm
Cut 2

1 Inch
1 cm Print Guide