Thread: Making foam bones

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So I need to figure out how to make some foam bones that will slide over pvc, I'm thinking using the pipe insulation and maybe some foam craft balls and tape to get the shape then go over them maybe with drylock to hide the seams and give it a good texture, then just paint them, this is going to be for my scythe that I'm making, each bone needs to be abour 2 ft long, any ideas or suggestions would be appreciated.

First, I would consider using EMT conduit instead of PVC pipe. Should be able to get stronger pole while smaller diameter.

As for the bones, I would do the insulation and tape, but then a layer or two of mache over that before painting.

My only concern is, that I want to be able to break this down into four sections, now I know with pvc I can use caps and stuff to screw sections together, this will make it easier for storage, can I do that with the conduit?

Yes, though, you'ld be looking for COUPLERS on the straight section, and then the TEE would be a little different. A trip to the hardware store and it should be fairly straightforward how they fit together. There's compression coupling, or even just set screws:

Find Metal Conduit - Couplings and other Electrical Fittings at Aubuchon Hardware (far from the cheapest place, but the first that had pics.)

I would consider doing the bones as mache over a tinfoil/newspaper framework (around the pipe) as Devils Chariot did here: The Devil's Workshop: Wacky Zombie - Part 2. Fabricating a Body from Scratch

Might i suggest Great Stuff spray foam. Cut the PVC to the size of each bone, spray a little foam on each end, let it set up and carve. The suff sticks to PVC great.

I usually buy up on clearance and use A LOT of the styrofoam Bag O' Bones. They are already formed and painted. You could half them and hollow out the centers to fit around your poles. With liquid latex you can then glue them back together, seal them up and reinforce them with liquid latex.

Works for me.