Eivor Cosplay: Axe

Eivor Cosplay

I started creating an axe from EVA foam to go with my Eivor cosplay from Assassin’s Creed Valhalla.

I lost steam halfway through this project with us going back into lockdown here in Melbourne and my event I was going to wear this costume to was cancelled. I still wanted to document how far I’d gotten with it anyway, in case I decide to come back to this so apologies for the half-finished post!

As usual I started with some screenshots from the game Assassin’s Creed Valhalla. When I started this project I hadn’t upgraded this axe to its final design so this is the one I started with.

Screenshot of the axe

Just like the other foam elements for Eivor I loaded the screenshot as a canvas in Fusion 360 and traced over all the key elements.

Fusion 360 sketch of the axe

I used a PVC pipe as the main handle of the axe so I used that as a base to adjust the sizing of the rest of the axe. I think I printed at least 3 different sizes of the blade to try the different sizing.

Then I traced the blade shape into EVA foam and extended the part that attaches it to the handle so that both sides are cut from a single piece. This way, I could roll this piece around the handle for a really secure fit and glue the two sides together for a thicker blade. I glued everything in place with contact cement.

I then cut out strips of 6mm EVA foam for the raised details and again glued these to the axe. I had to take care to cut them accurately so that the seam was minimal.

Then I covered the remainder of the axe with 3mm EVA foam pieces, again taking care to try to minimise the seam - I messed up on this big section of the handle, but this will be covered up by fake leather in the future anyway. I did try using Dap Kwik Seal to seal up the loose edge but I think this is better used for much smaller cracks - so a worthwhile experiment.

Kwik Seal repair fail

To make the end detail I cut out cones of EVA foam and glued them together and this time I instead used foam clay to seal up the edges. This worked much more seamlessly as it was difficult to glue the foam with a neat seam especially at the point so the foam clay filled in the gaps completely.

End of the axe detail with foam clay

The foam clay worked so well that I used it everywhere on the axe to fix any other gaps. I added some detail here (please note this picture is after priming it in the next step) to seamlessly merge the shapes between the EVA foam strip and the PVC pipe.

Foam clay between details

I don’t have a picture of the next step but I sanded down the blade of the axe to create the sharp edge in the same way I sanded and shaped my Skyrim Daggers. This picture is taken after priming but it shows the shape.

Blade of the axe

After I had the shape pretty much completed I primed the axe with PlastiDip which is a rubber coating that sticks really well to EVA foam and gives a good base for painting. Here is the end section after priming where it’s very difficult to tell the difference between the foam clay and the EVA foam.

Primed end of the axe

I held the axe by the handle while priming because this part will be covered by leather in the future and won’t be painted, here is the primed axe… where I realised I forgot the balancing weight behind the axe head.

Primed axe

I will revisit this project in the future - stay tuned!

About Me

Engineer, maker, do-er...
I basically just like to make things.