The materials you need:
- Styrofoam slabs, 2 cm thick
- PVC tube, a coupler and T-section
- PVC glue
- Hot wire cutter
- Acrylic resin (2-component system)
- Felt, black and blue
- Thin cork sheet (for wrapping the handle)
- All purpose glue
- Liquid nails
- Acrylic paint
Step 1: Getting started
Cutting the styrofoam is done with a hot wire cutter. This is a perfect tool for cutting styrofoam without making a huge mess. Mine can be powered by batteries or an external power supply. I have an adjustable lab power supply, and this is the perfect solution for using with a hotwire cutter, because it gives you a bit of control over the temperature.
I glued everything together with liquid nails. Make sure it works on polystyrene, of course!