Deep Dive | A Cosplay Duet

Styrofoam can be used as a base for props, but should be coated with gesso to harden it. Gesso comes as a liquid and is used to harden pieces and seal out moisture. Also, if you're working with foam I would definitely recommend cutting the pieces and sanding them outside. The stuff gets everywhere.

Here are a couple of examples of props made of styrofoam:

Bond of Flame Keyblade

Chakrams

Series: Kingdom Hearts II
Character: Juusankikan Roxas
Cosplayer: Dark
Materials: Styrofoam, Gesso, Acrylic paint, White spray paint, Clear sealant, Plastic chain, Hot glue, Paper clips, Utility knife, Sand paper

I started with two large rectangular pieces of foam and cut them with a utility knife. First, draw the keyblade shape onto one of the large rectangular pieces of foam, and once you're satisfied then cut it out with a utility knife. Then use the second rectangular block to cut out the smaller pieces, like the spikes on the keyblade. Remember to watch out for your fingers; it's surprisingly easy to slip up.

Then sand the rough edges with sandpaper. Before moving on you may also want to reinforce weaker parts by sticking paper clips through them. They're really helpful - from holding up your wig to keeping props together.

Don't worry too much about all the rough edges - we'll do more sanding later. Just add a few good coats of gesso with plenty of time in between for them to dry. Make sure they're not too heavy so they don't drip - otherwise it really will dry heavier in some areas. After you're satisfied with the coats, it's time to sand down the gesso to get the finer bits.

For paint, I started with a solid base of white spray paint and painted the rest with black and red acrylic paint. The "chain" is actually pieces of a necklace that I took apart. I know I could have used a plastic chain, but this was easier at the time. Then I just finished sealing the paint with a clear sealant. Always remember to seal your painted props with some sort of sealant [matte or glossy] otherwise the paint might just decide to melt on your hands when you're holding it, and you'll end up with a mess.

Double check that you have everything, and you're done! Have fun with your new keyblade!

Series: Kingdom Hearts II
Character: Juusankikan Axel
Cosplayer: Ven
Materials: Styrofoam, Gesso, Acrylic paint, PVC Pipe, Lots of hot glue and paper clips, Sand paper

	Since the foam I bought was rectangular, I ended up having to split each chakram in half and then attaching it. When you sand foam, the stuff gets everywhere. A month of permanent squishy snow littered my floor no matter how much I vacuumed.
	I made it out of foam cause I wanted the angles of the chakrams, since they aren't flat - otherwise I would’ve used luan plywood. So not too hard.
	I carved the chakram out, sanded in the angles, glued and fastened the pieces together (with paperclips), covered it in gesso, and painted.
	Too bad they were too big and awkward to take on the plane. Oh yeah, if you’re going to fly to a con, plan your weapons with transportation and luggage constraints in mind!

All cosplays and props belong to Dark and Ven of Deep Dive Cosplay. All original characters, character designs, and other concepts belong to their respectful owners.

	I started with two large rectangular pieces of foam and cut them with a utility knife. First, draw the keyblade shape onto one of the large rectangular pieces of foam, and once you're satisfied then cut it out with a utility knife. Then use the second rectangular block to cut out the smaller pieces, like the spikes on the keyblade. Remember to watch out for your fingers; it's surprisingly easy to slip up. Then sand the rough edges with sandpaper. Before moving on you may also want to reinforce weaker parts by sticking paper clips through them. They're really helpful - from holding up your wig to keeping props together.
	Don't worry too much about all the rough edges - we'll do more sanding later. Just add a few good coats of gesso with plenty of time in between for them to dry. Make sure they're not too heavy so they don't drip - otherwise it really will dry heavier in some areas. After you're satisfied with the coats, it's time to sand down the gesso to get the finer bits.
	For paint, I started with a solid base of white spray paint and painted the rest with black and red acrylic paint. The "chain" is actually pieces of a necklace that I took apart. I know I could have used a plastic chain, but this was easier at the time. Then I just finished sealing the paint with a clear sealant. Always remember to seal your painted props with some sort of sealant [matte or glossy] otherwise the paint might just decide to melt on your hands when you're holding it, and you'll end up with a mess.
	Double check that you have everything, and you're done! Have fun with your new keyblade!