DIY Foam Axe Prop!
by VanOaksProps
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What this video covers
VanOaksProps walks through the full build process for a foam replica of Jack Torrance's iconic axe from The Shining, designed to be lightweight and safe for Halloween haunts and convention use. The blade and handle are both constructed from EVA foam floor mats, shaped with a heat gun and Dremel, then finished with a multi-step painting process that mimics real steel and wood grain. Sponsored Surebonder Cosplay Stik hot glue is used throughout the assembly. The result is a screen-inspired prop that is durable, convention-compliant, and visually convincing.
Key takeaways
- ◆EVA foam floor mats are the primary material for both the axe head and handle
- ◆A multi-layer finish — including Plasti-Dip, wood stain, shellac, and graphite powder — creates realistic metal and wood textures
- ◆Surebonder Cosplay Stik hot glue is highlighted as a flexible, foam-friendly adhesive
- ◆The prop is intentionally built to be convention-safe (no hard or sharp materials)
- ◆The technique stack is transferable to many other foam weapon or horror prop builds
Who this is for
Cosplayers, home haunters, and prop makers who want to create a screen-accurate foam weapon replica suitable for conventions or Halloween displays.
Tools mentioned
- • box cutter
- • heat gun
- • Surebonder hot glue gun
- • Dremel rotary tool with cut-off wheel and sanding drum
- • 220-grit sandpaper
- • chip brushes
- • steel wool
Materials mentioned
- • EVA foam anti-fatigue floor mats (3/8")
- • Surebonder Cosplay Stik hot glue
- • paintable acrylic caulk
- • Zinsser Clear Shellac
- • graphite powder
- • Plasti-Dip rubberized spray
- • satin warm caramel paint
- • Minwax Dark Walnut wood stain
- • satin clear coat
- • burnt umber acrylic paint
⚠ Safety notes
Use heat gun with caution to avoid burns; work in a ventilated area when applying Plasti-Dip, shellac, and spray paints. Rotary tool use requires eye protection.
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