How to Make Devil Sword Dante EVA Foam Cosplay Sword from Devil May Cry 5 - Free Foam PDF Templates
by SKS Props
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What this video covers
SKS Props walks through the full build process for a large-scale EVA foam replica of Dante's Devil Sword from Devil May Cry 5, completed in time for DragonCon. The finished prop spans roughly 62 inches and weighs approximately 2.5 pounds thanks to a lightweight EVA foam and foam clay construction. Free downloadable PDF templates are available on the creator's website to help viewers replicate the build. The tutorial covers everything from cutting and shaping the foam core to sealing, priming, and painting the blade's signature Damascus-style pattern.
Key takeaways
- ◆Free PDF templates are available for download on the SKS Props website, making it easier to replicate accurate proportions
- ◆The sword is built around an internal armature of PVC pipe or wood dowels for structural support while keeping overall weight low
- ◆Multiple sealing layers — including Flex Seal, Plasti Dip, and Flexbond — are used to prep the foam surface for paint
- ◆Graphite powder and acrylic paints are combined to achieve the metallic Damascus blade finish
- ◆Foam clay is used to add fine sculptural details that would be difficult to cut from flat foam sheets
Who this is for
Intermediate-level cosplay prop makers and Devil May Cry fans who want to build a screen-accurate, convention-ready Devil Sword Dante replica using EVA foam techniques.
Tools mentioned
- • heat gun
- • Dremel
- • Dremel flex shaft
- • hot knife/wood burner
- • large utility knife
- • small utility knife
- • hobby knife
- • cutting mat
- • hot glue gun
- • mechanical pencil
- • punches for foam
- • 123 blocks
- • brushes (mop, filbert, liner)
Materials mentioned
- • EVA HD-Foam
- • foam clay
- • PVC board
- • PVC pipe
- • wood dowels
- • 3M Foam Fast adhesive
- • contact cement
- • Bob Smith super glue
- • Flex Seal Clear
- • Plasti Dip
- • Flexbond
- • Liquitex Ceramic Stucco
- • Utrecht Pumice Acrylic Medium
- • Liquitex Heavy Body Acrylics
- • graphite powder
⚠ Safety notes
Use heat gun and hot knife in a well-ventilated area and exercise caution to avoid burns. Contact cement and spray adhesives should be used with adequate ventilation.
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