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Make a Viking Axe out of Foam board (Bearded Axe): Part 2

In this part of the tutorial we build the axe.



Trace axe

Place the axe template on foamboard and trace it. Do this twice. You want two of these.

Trace axehead wraparound

Do the same thing with the 5a-5b axehead wraparound part. But you only need one of these.


Trace out the handles

Use the axe template to trace two handle pieces. Just trace the complete handle. Do not trace the blade portion. Notice the dotted line here in the picture.

You now have five parts traced out.

Cut out the pieces

Cut out those five pieces.


Will's Tip on Cutting Foam board: Don't try to cut all the way through it in one swipe. Use a really sharp blade and make three passes. the first pass just cuts the top layer of paper. Second pass cuts the foam and the third pass cuts through the bottom layer of foam.


Glue the pieces together

Now set aside the axehead wraparound. And glue together the four main pieces to form the axe.


The glued stack

It forms a stack and is nice and strong.


Clena up the edges

With a stack of four layers there is going to be some inconsistencies so use a sharp knife and clean up all the edges so it is all nice and even.


Sand the edges

And if you have sandpaper use it to smooth out all the edges.


NextNow let's work on the blade bevel and the axehead wraparound piece. (continue)


Foam board

Elmer's Acid-Free Foam Boards, 20 x 30 Inches, 3/16-Inch Thick, Bright White, 2-Count (902015)

If you are looking for high quality, archive quality or you are looking for a backing for photographs you should use an acid free foam board It is more expensive per sheet though.


Xacto knife

X-ACTO #1 Knife, Z Series With Safety Cap

Make precise, fine cuts every time with the X-ACTO #1 Z-Series Knife with Safety Cap. This knife features a #11 fine point zirconium nitride-coated blade for sharpness and strength, and the lightweight aluminum handle enables you to make agile cuts with ease. This X-ACTO knife cuts through a wide variety of materials including paper, plastic, balsa wood, and thin metal. An easy-change blade system lets you swap blades quickly to meet the needs of any project, and the included safety cap offers easy portability.


Hot glue gun

Will's Favorite Hot Glue Gun

Surebonder PRO2-100 100-Watt High Temperature Industrial Glue Gun, Black