Styrofoam Halloween Props




About: Malmey Studios was collaborated in February 2010 By Jeremey & Mallie Adams. The premise of our work is to build high quality movie props and custom made costumes. Our work has ranged from Creature Reache...

Ok, This is my first instructable so please be kind.

this whole thing started with my gf's friends son wanting a Skeletor staff! Thats why its a Ram Head, However this will work for any prop. Im going to try a wolf head next!

Anyway He didin want to pay the price for a real ram skull nor could he find a "GOOD" prop made skeletor staff on ebay. So I took some extra styrofoam and made this!

Step 1: Materials

Here are som of the materials you will need!

Jig, Skill or Hack Saw

Step 2: Draw Out Your Pattern

     Ok do some research and find some images you want to cut out. Again I picked the Ram Head! Start by drawing directly on your Styrofoam. Make sure you rough sketch all your details in.

Step 3: Cut Out Your General Shape

With your drawing and detail added its time to choose your weapon (saw) and go to town. Leave yourself enough room to do some edging and sanding later! In the second picture you can see I did not cut all the way to the line.

Step 4: Edge and Shape Your Prop

Ok here is where your hack saw, sanding paper and dremel will come in handy! You'll want yo srart shaping your prop. I took the hack saw and did a "rough" cut all the way around the prop, i also did this at an angle to assist in rounding the corners. I used my Dremel to sand down into the prop to make voids and crevices. I then took my sandpaper and smoothed out, roughed up and shaped all the areas.

Step 5: Primer Your Prop and Acess

This step is ecactly what it says, Primer your prop. Srpay paint will desoulve your styrofoam a little but this is ok. It gives it a little of a decayed look, perfect for a halloween prop. This is a perfect time to shape out any acessories cut em sand em and primer em! Give your paint some time to dry. The styrofoam will stick and tear if you do not!

Step 6: Attach Your Acessories

You will not need to attach your acessories and any other parts and pieces to finish your prop! I used gorilla glue whis was perfect for this project, it expands and work great with the foam. Dont worry about the glue expanding it can be sanded off easy enough. Now I used finisning nails to hold my pieces in place while the glue dried, again give it 24 hours! I left the nails in the prop for a little extra stability!

Step 7: Finish Your Prop

Now its time to finish your prop.Sand down any rough spots including glue expansion, Paint and detail!

Simple as pie! You now have a creepy halloween prop. Im this case I now have to paint this thing purple and attach it to a staff. Wish me luck and Keep on making Stuff!

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    8 Discussions


    7 years ago on Step 5

    Gesso, used to prime artists' canvas, won't dissolve your foam. It's also cheaper than spray primer. :)

    1 reply

    7 years ago on Step 5

    There IS a brand of spray paint that will not dissolve styrofoam: DESIGN MASTERS. Created for use by florists, it can be found in craft stores like Michael's, and comes in a nice array of colors and metallics.


    8 years ago on Step 7

    The horns are very smooth, impressive, and I liked the way you've used the dissolving effect of the paint to add to the texture of the ram's skull. Well done!

    1 reply

    Reply 8 years ago on Step 7

    Thanks I apprichate it!! I worked pretty hard on this one! Im thinking of using it as a costume mask next year. Like the head for a wire harness based costume!


    Thanks alot. As for scale its 19 inches high. As for the styrosnow it ended up in places I had no idea to could even go. Lol.


    8 years ago on Introduction

    That turned out GREAT !!! Its difficult to tell the scale though with only the sawzall blade as reference, just a suggestion.. Styrofoam is fun to work with but cleaning up all the styroSNOW is next to impossible! Thats one reason I try to work outside whenever Im using styrofoam. Bet this earns you a LOT of coolguy points with the gf's main man