Anyone know how to form a shovel head from foam?

[Aloobarber]

I'd like to build myself a replica of the shovel from bf1, because why not, and think that heat shaping the head from foam would be a good idea. Problem is, i have no idea how to get the specific shape, or get the right length, as the only foam i can get my hands on right now is the a4, 3-4mm stuff.

reference:http://www.ebay.com/itm/1916-Imperial-Russia-WWI-Military-Spade-Shovel-Mark-/250785528159 - this seems to be exactly what the model in the game is based off of.

Any help/ tips you can provide would be of great help, as i've never really worked with foam before

Cheers

 

[penabled]

After googling a bit it seems that an over all length of 20 inches is about right.

There are plenty of tutorials online about how to heat form EVA foam. Use a heat gun, the same kind used for removing wallpaper and house hold paint. Also nothing says you can't glue two sheets together to make it thicker if that's what you need. Use a spray on adhesive for that.

Could also use coat hanger wire around the edge to help it hold it's shape.

 

[Aloobarber]

After some experiments last night, I think some plastic sheets/ worbla would provide a sturdier shape than the foam, but from what I can work out, the overall technique seems to be fairly similar, if not the same.

All i have to do now is find some. Which could take some time.

 

[penabled]

I found small sheets of styrene in various thicknesses at a Parkrose Hardware. I think that even Home Depot might have something similar.

 

[Aloobarber]

I have a few styrene sheets, and I can find them fairly easily without losing an arm and a leg, but trying to find thermoplastic in the UK for relatively affordable amounts is harder than I initially thought

 

[penabled]

Thermoplastic? I found sheets of kydex at a leathercrafting supplier. Maybe there's a Tandy Leather nearby.

 

[Aloobarber]

After a quick search of kydex, I found an eBay seller selling sheets of various shapes and sizes, for fairly decent prices.

 

[penabled]

Kydex can be easily shaped with a heat gun...just don't hold it for too long in one spot as the kydex will blister and boil and once that happens it cannot be undone. Also...gloves

 

[Aloobarber]

Ok, thanks for the advice. Will definitely make sure not to forget gloves

 

[penabled]

I was just thinking that the blistering effect might actually be useful as a weathering technique if done sparingly....might look like it was corroded and stuff.

 

[Aloobarber]

Yeah! Combine that with some hammered metal effect spray paint, and I think that'd look pretty sweet!