EVA Foam is a durable but easily workable foam that is soft yet firm. It is great for weapons and armor for LARP and Cosplay.

In this tutorial I show you how to make a double bladed axe out of EVA foam. And I include the template which makes it even easier for you to make.

The Template is here

I also have a video tutorial for this project at the bottom of the page.

Note:I am working on the tutorial right now!

Overview of the Project:

EVA Foam is really very suitable as a fun weapon material. It has a firmness yet it is soft. So, it makes for good Boffing, Larping and cosplay. And it is pretty easy to work with. You can also use a heat gun on it and make shapes and curved armor. In this tutorial we make a pretty straight forward Double bladed axe that looks good but can be used for fun. No need for a heat gun with this project.

The EVA foam is for the blades of the axe. For the handle you can improvise anything including a wooden dowel, broomstick or a length of PVC plastic pipe.

I was concerned about cementing the EVA foam to the PVC pipe handle so I ran a test using 5 different adhesives. Watch the video to see which of the 5 was no good! The other 4 worked perfectly.

The five adhesives I tested are

• PVC Cement (Special cement made for plumbers and PVC pipe)
• E6000 Adhesive
• Gorilla 2 part epoxy
• Barge Cement (Frequently used by people for EVA foam projects)
• Hot Glue gun

Four of the five worked just great and are suitable for adhering EVA foam to PVC piping. The only one that didn't work was the Gorilla 2 part epoxy. In this tutorial I went ahead and did the project with hot glue because that is the easiest and the fastest.

Tools and Materials:

• Interlocking Anti-Fatigue EVA Foam Floor Mat
• Surebonder Glue Gun, Black
• X-acto knife
• Speedball Screen Printing Ink: Silver 8oz
• 1 24" lenght of one inch PVC plastic pipe
• 1 scrap of leather for the handle. You can improvise something different.

Earn a Certificate of Contribution!

If you make this project email me a picture! I will email you a certificate of completion from stormthecastle.com You can print it up and hang it on the wall.

My email:

Thanks for visiting my website! I hope you make this project!! Would you consider a donation of $1 to support my work? Paypal makes it very easy and safe. Click here to donate $1 - Every little bit helps Will to keep making great tutorials and templates. Thanks!

Let's Get Started!!

Print up the template and cut out the axe head that you want to use for your axe. Place it on the sheet of EVA foam and trace it with a black marker. I tried white pencil but that didn't work. A sharpie works really well. Trace two of them.

Go ahead and cut those axe heads out. Use an x-acto knife and replace the blade as often as needed. You need a really sharp blade to cut the foam easily.

Draw bevels on the blade edge of the axe heads. It is about 1/2 inch wide.

Then cut the bevels with a very sharp knife. Change the blade often!

Okay! More resources lower down on the page. Or you can continue with the tutorial right here: Make an EVA foam Double Bladed Axe part 2

The Video Tutorial is here:

PRODUCTS AND TOOLS USED IN THIS TUTORIAL:

On amazon.com this is the exact foam that I bought for this project (And for some other projects): Interlocking Anti-Fatigue EVA Foam Floor Mat

Will's Favorite Hot Glue Gun

Surebonder PRO2-100 100-Watt High Temperature Industrial Glue Gun, Black

X-acto designer series knife #1 blade

Speedball Opaque Fabric Screen Printing Ink Colour: Silver 8oz