Giant Popsicle Prop
by JustinFogarty in Craft > Costumes & Cosplay
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Giant Popsicle Prop
Hello Instructables! Long time lurker, first time poster. Let's go!
Cost to make: $40
Supplies
Materials
2x 24",24",1" rigid pink insulation foam board
1x 20",3.5",0.25" wood plank
semigloss latex house paint
1x small tube latex caulk
glue
wood sealer
joint compound or body filler
Tools
jigsaw or router sander
hot wire foam cutter
wood clamps
scraper/putty knife
paint roller
chip brush
caulk gun
Cut Popsicle Stick
Cut the board to 20" of length. Round the end using either a router with a flush trim bit and circle template or a jigsaw. I cut corners and used a jigsaw (hah, get it?). Use scrap as a sacrificial holder while making the popsicle. Sand the edges smooth.
(Optional: Woodburning a Design/Text on the Stick)
This is the point where you would woodburn the stick, if you choose to do so. I wish I would have.
Seal Wood
I used Thompson's Clear Water Sealer. You won't have to worry about leaving brushstrokes, so use an old brush or chip brush to apply.
Cut and Shape Foam
Using a hot wire (in a well ventilated area), cut each board in half making 4x 24",12" pieces. On one piece, round 3 corners and carve a bite mark in the fourth. This piece will be used as a template to cut the rest of the pieces flush as you glue them together. Curve out a recess in two foam pieces for the popsicle stick. Glue, clamp, carve, repeat. I used hot glue but it didn't stick well. Try spray adhesive?
Bodywork
As this was a commissioned piece, I was working with a limited budget. Automotive body filler would have been preferred, but pricey. I used drywall joint compound. Round over all the edges with a sander and apply your filler with a putty knife. Sand smooth.
Paint
For the first layer pour the paint to achieve a drippy finish, making sure to make a huge mess. For the second layer use a roller because pouring was a bad idea.
Caulk
Remove your sacrificial popsicle stick and insert the finished stick. Glue in place. Add a healthy glob of caulk to the base of the popsicle stick. Allow to cure, and cover with paint.
Finished!
Good job. Now go hit your friends with it.