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How To Carve Foam Props


hey guys welcome back i’m nate with the
king of random and today we’re gonna be
showing you how to make your very own
replica from a video game in a recent
video i got to show you something fun I
built for Devin Supertramp some giant
Mario Kart shells that I drove around on
remote-control cars like I said I would
I’m now going to show you how I did it
so you can make your own no interest in
Mario Kart that’s all right you can use
the same methods I’m gonna show you to
make whatever kinds of props you want in
the video where I showed these shells
off I had these giant 2 foot fiberglass
shells we’re going to be scaling those
shells down so it’s a little bit more
manageable but the same principles can
be used for smaller or much larger
projects the purpose of today’s video is
to learn how to sculpt and prep one foot
Mario Kart shells out of foam the
materials for this are pretty basic this
is called rigid insulation foam it comes
in sheets that are about 1 or 2 inches
thick and you can usually get it in pink
or blue at hardware stores the full-size
sheets are usually 4 feet wide and 8
feet long to make it so I could fit the
pieces into my car this one is cut down
to 1/4 of that size so it’s 4 feet long
and 2 feet wide this is the 2 inch foam
and it’s what we’re going to be using
today these shells are tall and almost
spherical in shape so we’re gonna cut
out 6 of the squares from the foam glue
them all together and that will give us
a 1 foot cube
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we have our marks measured out and now
we’re gonna use this handheld miter saw
to cut out the individual squares
we have our six squares cut out and
we’re ready to glue them together but
this foam is made from polystyrene which
can be dissolved by the solvents and a
lot of types of glue so what we’re going
to use is this expanding foam in a can
it glues the foam together really well
and it doesn’t dissolve it shake your
can of expanding foam well
apply a thin layer of the foam and press
her next piece down on to it I like to
use bamboo skewers stuck in through the
sides to keep it from sliding sideways
while it dries
[Music]
blew all six pieces together using
skewers on each layer and place a weight
on top to help minimize the expansion of
the foam always wear gloves when we’re
using this expanding foam because it’s
really sticky and very annoying to have
on your skin also make sure you’re
wearing clothing it you’re okay with
getting dirty depending on the
temperature and humidity the foam will
take an hour or two to dry completely
once it has it will be rigid and
inflexible our expanding foam is dry so
it’s pull out the bamboo skewers
sometimes they’re glued to the foam on
the inside so it’s good to have a pair
of pliers to help with grip that one
doesn’t want to come out we’ll probably
run into that skewer while we’re trying
to carve the foam it’ll be a little bit
annoying but we just cut it off as we
get to it our foam is now ready to go so
let’s start marking out the design from
the top down these shells are fairly
round so I’m going to draw an ellipse on
the top of the foam and then carve off
all the sides until we have a cylinder
I’m going to be using the same handheld
miter saw that I use to divide the
squares up it’s narrow and it’s straight
and it does a really good job of cutting
through the foam quickly
[Music]
after the quick cut with the sauce and
very rough sandpaper will help you take
down the ridges left in the foam now we
have our cylinder let’s start adding
some basic details these shells have a
ridge around the middle with a little
bit of a curve in it so I’m going to
draw that in first I’m just adding a
mark where the front and the back are so
I know where the curve should begin and
end this line I’m gonna draw that goes
all the way around will be the highest
point that I want the ridge this second
line will be the lowest point of the
ridge
[Music]
you can see that I’ve now drawn this
band going all the way around I’m now
going to use a thin razor blade to cut
about an inch in all the way around the
band so that when I cut down from the
top the piece will break off there’s a
bamboo skewer that wouldn’t come out of
the foam I just sliced right through it
with the saw
now we do the same thing on the other
side sounds like bamboo is okay guys
update we can now start to see the very
basic shape of the shell start to emerge
and it’s time to take down the excess
and give it that nice dome shape you can
use a soft for taking down the large
pieces of if you want but one of my
favorite tools for shaping this foam is
some 36 grit sandpaper it’s very rough
and takes down the edges quickly
[Music]
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okay we’ve got a dome for the top of
Michelle coming along quite nicely now
let’s move on to the bottom of the shell
on the bottom these shells do have
something of a neck at the front which
looks a little bit like a doughnut so
the first thing we’re gonna do is carve
out a place for that first we’ll draw a
line to keep it centered
now let’s take our razor blade and do
the same thing we did with the Ridge
going all the way around I’ll cut a
round of the neck and then sawed down
pieces of the foam to that point
now that we’ve got the neck blocked in
let’s go back to using the saw in the
same paper to take off more foam and
block in the bottom shape of the shell
[Music]
we’ve got our basic shape carved in now
let’s open up the neck hole and sand
down and refine all of our edges to open
up the neck hole you could use sandpaper
or razor blades if you’re really patient
but I’m going to use a rotary tool to
speed things up a bit
[Music]
[Music]
yeah Foam everywhere just it gets
everywhere now that we’ve taken down the
ridges let’s go over the whole shell
with a high grit sanding sponge to
smooth it all out we smooth down the
shell and now the only thing left to do
is put in the four indentations that are
the turtles leg holes
[Music]
[Music]
our shell is carved and smoothed down
now all that’s left is to carve in the
shell ridge pattern on the top and the
belly lines on the bottom after I draw
in those lines I’m going to carve them
in using sandpaper wrapped around a pen
[Music]
now that we’ve added in our ridges this
shell is ready to prep for the mold if
you remember I explained that there are
a lot of chemicals that can melt the
polystyrene that this foam is made from
so what we’re gonna do is cover the
entire thing in a protective layer of
latex house paint that will form a
barrier that will let us do minor repair
work and apply mold rubber that won’t
stick too much to the foam since the
color we’re going to be using doesn’t
matter at all
you can usually go to a paint store and
ask if they have any incorrect mixes
they’ll often be sold at a steep
discount
[Music]
there you have the paint is dry and the
only thing left before our shell is
ready to mold is to use a little bit of
spackle to fill in any gaps or cracks or
pieces that may have chipped off in the
carving spreading this spackle a little
bit to try and fill in some of the
really rough texture now I’ve got lots
of the gaps in cracks filled with the
spackling I like this kind because when
it’s wet it’s a very bright pink color
but as it dries it starts turning white
so you know when it’s ready to sand or
paint here we go the pink spackling has
all turned white which means it’s ready
to be sanded and as soon as we’ve done
that the whole shell will be ready to be
molded I’m using 400 grit sandpaper just
to smooth down spackle
[Music]
there you have it our turtle shell is
now built sculpted fixed up and prepped
and it’s ready to be molded which we’re
gonna show you how to do in our next
video to recap our process we took some
two inch rigid insulation foam and cut
out six squares one foot by one foot
using expanding canned foam we glued
those six pieces together into a 1 foot
cube we then carved it into the shape of
our shell using a saw and some high grit
sandpaper once we had the shape that we
wanted carved out of it we painted on a
protective layer of latex house paint
and then you spackling to fill in any
gaps or cracks in the foam and now it’s
ready to be molded this is the exact
same process that I used to make
mariokart shells for the Devin
Supertramp video here’s the foam shell
from that build as a reminder you don’t
have to use these techniques to make
shells all sorts of shapes can be made
this is just one fun example there you
have it now you know a quick method of
making custom designs of your favorite
video and movie pieces thanks for
joining us for this project today and we
look forward to teaching you how to mold
and cast your creation in the next video
talk to you then there’s so much static
electricity on the foam that I try and
brush it off and then all of the foam
just like comes flying back on it’s like
a magic trick
appearing foam dust
[Music]
well it’s everywhere oh my gosh that
made it worse hey guys I hope you’re
enjoying these new videos with Nate as
much as I am he’s got some phenomenal
talent when it comes to building and
crafting and he really loves what he
does
give him some validation if you agree
and I’ll see in the next video
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