Let me say this was the first attempt at building a prop out of foam. and for the most part I am really happy with the results.
I created a simple jig for my router with multiple holes for the various radius i wanted to cut. All cuts were made 1/2" deep in 2" thick foam, with the exception of the outermost radius.
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I ended up having to glue a temp plate onto the foam sheet since the foam itself did not provide enough rigidity to to act as the center pin for the jig.
![Circle Diagram Pattern]()
I did each radius and copied the work on the back side of the foam. this was repeated for all circumferences to make the wheel.
![Circle Recreation Table]()
Once the circles were cut I laid out the spokes of the wheel in the shape of bones. at first I tried to use a cheap foam hot knife which proved to be too slow and worthless
![Architecture Drawing Circle Illustration]()
In the end I used a jigsaw with a wood blade and it cut through the foam like butter. I cut out each void area in the center of the wheel. I did not cut the outer handles out yet as i wanted to minimize the chance they got damaged while shaping the spokes.
![Bicycle wheel Wheel Spoke Bicycle tire Rim]()
I started to shape the spokes with a drywall rasp
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![Wheel Spoke Product Alloy wheel Rim]()
![Wheel Product Alloy wheel Spoke Rim]()
All surfaces were sanded with 120 grit paper to smooth them down from the work with the rasp. With the rough shape having taken form I wanted to add something to the rim of the wheel to make it pop. I laid out the lettering by hand and used a soldering iron with a fine tip to cut the letters in. This had a great effect like it was done with an old tool. I tried a dremel and attachment on a test piece but found it looked to machined. At the same time as doing the letters I put the first coat of west system epoxy on the spokes and glued the cut foam skull for the center in place.
![Alloy wheel Wheel Spoke Rim Product]()
![Wheel Spoke Automotive wheel system Rim]()
![Eye Jaw]()
The exterior handles were then cut out and shaped as well. The whole thin then got two additional coats of epoxy to strengthen the shell and allow for spray paint to be applied. Given it was my first time working in foam I choose epoxy I had worked with before. The wheel will also be in a location where it doesn't get handled. I welcome any comment on what would have kept the detail and made it even stronger.
![Wheel Product Spoke Rim Automotive wheel system]()
Two coats of spray pain were applied to give it a brown/grey base color followed by multiple coats of diluted acrylic paint to give it some depth.
![Alloy wheel Wheel Tire Spoke Rim]()
Finish paint and ready for mounting
![Wheel Alloy wheel Spoke Rim Automotive wheel system]()
Pictures from final placement
![Light Darkness Fictional character]()
![Wheel Spoke Rim Auto part Automotive wheel system]()
I created a simple jig for my router with multiple holes for the various radius i wanted to cut. All cuts were made 1/2" deep in 2" thick foam, with the exception of the outermost radius.
I ended up having to glue a temp plate onto the foam sheet since the foam itself did not provide enough rigidity to to act as the center pin for the jig.
I did each radius and copied the work on the back side of the foam. this was repeated for all circumferences to make the wheel.
Once the circles were cut I laid out the spokes of the wheel in the shape of bones. at first I tried to use a cheap foam hot knife which proved to be too slow and worthless
In the end I used a jigsaw with a wood blade and it cut through the foam like butter. I cut out each void area in the center of the wheel. I did not cut the outer handles out yet as i wanted to minimize the chance they got damaged while shaping the spokes.
I started to shape the spokes with a drywall rasp
All surfaces were sanded with 120 grit paper to smooth them down from the work with the rasp. With the rough shape having taken form I wanted to add something to the rim of the wheel to make it pop. I laid out the lettering by hand and used a soldering iron with a fine tip to cut the letters in. This had a great effect like it was done with an old tool. I tried a dremel and attachment on a test piece but found it looked to machined. At the same time as doing the letters I put the first coat of west system epoxy on the spokes and glued the cut foam skull for the center in place.
The exterior handles were then cut out and shaped as well. The whole thin then got two additional coats of epoxy to strengthen the shell and allow for spray paint to be applied. Given it was my first time working in foam I choose epoxy I had worked with before. The wheel will also be in a location where it doesn't get handled. I welcome any comment on what would have kept the detail and made it even stronger.
Two coats of spray pain were applied to give it a brown/grey base color followed by multiple coats of diluted acrylic paint to give it some depth.
Finish paint and ready for mounting
Pictures from final placement
Beautiful work!!!!
