Instructables
This is how to build a Rocket Launcher from Team Fortress 2 for cosplay or to decorate your mantle.  This was made at LVL1, Louisville's Hackerspace.  (see more at http://www.lvl1.org)  Be sure to check your area for a hackerspace, they're a great place to meet new people, learn new things and get access to awesome tools.

http://tf2wiki.net/wiki/Rocket_launcher

The really awesome thing about this build is at the con you feel like you're in the game.  Most prop guns don't show in your field of vision but this thing sitting on your shoulder looks exactly like what you see in game which makes being a solider even more awesome. 

Materials:
4.5" diameter PVC pipe
2" thick insulating foam
0.5" thick insulating foam
24x36" sheet metal
1/8" craft foam
small piece of 1/2" wood (for the handles)
1/8" wood or other solid material
modgepodge
lots of hot glue
paint
 
Remove these adsRemove these ads by Signing Up

Step 1: Preparing the foam

Cut the 4.5" PVC pipe down to 17".  We'll need this when turning the foam to make sure the pieces fit. 

The tip of the rocket launcher is the easiest to start with.  The pics are for the wooden bit, but the steps are the same for the two parts.  Cut three 6"x14" pieces of 2" foam and glue them together.  A simple hacksaw works well on foam, plus you can put it at an angle and make some long cuts.  Go easy on the glue, the more you add the harder it will be to cut the and the less round your final piece will be.  I usually go with one light coat on both sides; let the glue dry for a minute then press the two halves together with some bricks or something heavy.  If you're worried about the foam flying apart on the lathe, don't.  It doesn't hurt that bad when the pieces hit you.  :)

When turning foam, always cut the pieces as wide as your foam is stacked.  This way you can make a piece as close to round as possible before putting it on the lathe.  It's going to be rough to turn this down to a circle and the closer to round it is starting off the less likely it's going to fly apart or break.

Cut the corners off the glued together block so you end up with an octagon.

Hi, awesome rocket launcher!! My son is dying for one of these for his Halloween costume. I am a single Momma and there is no way I can build this thing! lol Is there any way you would consider building one for us? Of course, we would be willing to pay you for the materials and your time. Thank you!

this is awesome. Do you think I could carve the wood piece out of actual wood (like Pine)?

that part, and the front of the barrel at the end?

gadams21897 months ago

You should make a sentry or a dispenser. That would be killer

Fuego652 years ago
Waah, this is well-done, I would like to make the same, but, I got aquestion: Lengths are in inches, is not it?
(Sorry for my bad english)
RedWagon (author)  Fuego652 years ago
They should be in inches, I glanced through and the only part that might be in mm would be the handle.svg but I believe that includes unit data so it shouldn't pose a problem. Let me know if there's a specific part you have trouble with.
D00M992 years ago
Have you had any issues with the pink insulation foam snapping/in danger of snapping yet? I've heard it's brittle, so I get all antsy when the foam is being made into something long...
RedWagon (author)  D00M992 years ago
I also think layering the foam adds a lot of strength since the glue makes a nice thick, rubbery layer in between the foam pieces.
RedWagon (author)  D00M992 years ago
The foam is pretty strong structurally, the biggest problem is it dents easily. The cone also likes to come loose because the hot glue joint will just slowly rip off a layer of foam. I usually add some more glue to the cone before every event so I can stand it up without it leaning.
Poptart08092 years ago
awesome! do a spy eletro-sapper next!
Konradecai2 years ago
Someone deserves a high five. Come here, Cupcake
vulcan242 years ago
I like the soldiers stash you got going on there ;) There needs to be more of these
I dig it! Foam on a lathe, I need to try that.
Darkcast2 years ago
The girls with the toilet cannon is pretty sexy
Can you make a tutorial on how to make the costumes and the Max's Severed Head Hat? Cuz those are awesome..
hopporto2 years ago
FIRST. also this is pretty awesome