If you’ve watched the anime Seven Deadly Sins you’re undoubtedly a fan of the Dragon handle. I really wanted to make one and started searching the internet for 3D print files, when I realized, this would be a perfect project to make out of EVA foam. I’ve done some EVA foam builds before but never in a video, so I thought this would be a great opportunity to show ya’ll how easy and awesome EVA foam is to work with, especially for cosplay props.

Supplies

- EVA Foam

- Tools to cut it and shape it

- Paint (spray paint, acrylic craft paints)

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Step 1: Cut Out the Template

Like most foam projects, we are gonna start off with a template, to cut our foam out to the right shape, and to get that template I traced out a reference image in illustrator.

Step 2: Trace the Tamplate

The next thing you'll want to do is trace out your template onto the foam. So to make my handle thick enough, I’m going to cut out two pieces of foam, making sure to reflect the design so that I can keep the clean side on the outside

Step 3: Cut Out Your Foam

Next you'll want to cut out your foam, you can use an exacto knife or if you have a bandsaw, that works great to give you fast and accurate cuts.

Step 4: Glue Halves

Using spray adhesive, I glued my halves of the handle together.

Step 5: Shape the Foam

Using a rotary tool and a belt sander, I rounded off my edges to not be so sharp.

Step 6: Put on the Scales

To make my scales I bought a file on etsy to cut out onto my vinyl cutter and I cut out a bunch of scales, then painstakingly glued them on. It was worth it though because the result looks pretty awesome!

Step 7: Make Spikes

My spikes I ideally would have made out of foam clay but I didn't have any so I used normal modelling clay instead.

Step 8: HIlt

To make the hilt, I traced out my parts using the template, using three layers of foam to build up thickness, then I carver out the middle so it would sit nicely on the handle.

Step 9: Plastidip and More Plastidip

To cover up the color of the foam, I really had to use a lot of plastidip but that was ok because it gave me a really nice base coat for my paint.

Step 10: Painting Time

To paint my the handle I first used a darker shade of green and gave it a light dusting, then went back over with a heavier coat of lighter green and shaded certain areas.

The hilt I masked off and painted the separate halves, and then using a brush, I painted the screw heads silver.