Chainsaw Man Template
Hello everyone,
As a fan of the manga, and to join the chainsaw man cosplay project video, I created my own Chainsaw man cosplay . In this article, I'll show you how I crafted my Chainsaw Man helmet and blades.
I started by researching online for tips and found two helpful videos: "SKS Props" : https://www.youtube.com/watch?v=MKlDlGU_l5Y and "Seig." : https://www.youtube.com/watch?v=Auxli9B0nkg
I used the free template provided in the SKS Props video and followed Seig's video for additional details.
Helmet Shape
The first step was to create the upper part of the helmet and the head blade following the template.
For the front part, I used thick (1 cm) EVA foam to give it a more robust appearance and to hold the blade.
For the back of the helmet, I used lighter EVA foam (6 mm and 4 mm) since it was constructed from multiple layers and didn't need to be as solid as it will only hold some small parts
To make the head blade, I used light cardboard (2 layers of 5mm) to keep it light and straight. Although I initially intended for the head blade to be detachable from the helmet for ease of transport, I found it too difficult to make it both lightweight and sturdy enough to maintain its shape without moving., so I ended up gluing it to the helmet from the inside.
Chin shape
Next, I moved on to the chin shape. I used the template from the video on thick EVA foam. To create the teeth, I used basic white soft clay on toothpicks. I used a soldering iron to draw patterns and give an "organic" feeling to the top of the chin.
Helmet handles
I created the helmet handles using standard PVC pipes from a home center. The top handle is not glued but cast into the foam so it could rotate, making it easier to transport and display at different angles.
Blade Teeth and Details
To create the chainsaw teeth for the main part, I needed 50 teeth alternating between small and large sizes. I achieved this repetitive pattern by using a 3D printer. I designed two tooth shapes (long and short) and printed 25 of each
I also used the 3D printer to create a chain to connect the top and bottom parts of the helmet.
and design two exhaust pipes to attach to the back of the helmet.
All of the 3D print shapes can be found in my Thingiverse chainsawman collection.
On top of the 3D-printed parts, I added additional details using EVA foam, screws, bolts, etc
Painting
For the painting, I used metallic gray paint for the back of the helmet and blade and red for the front side (after priming with matte black paint).
I then brush painted a mixture of red and brown to give the blade an old blood effect. and voila the Helmet is done :
Hand blades
The hand blades were relatively simple to make. I cut the shape of my arm from light foam board (1 cm wide). For the blade teeth, I used a different shape than those on the head (see design here) to make them smaller and easier to move. I painted them with the same color scheme as the head blade: metallic gray and a mixture of brown and red for the blood effect.
Add a shirt and a black necktie and there you have it: a full Chainsaw Man cosplay !
Upgrades
Since i first crafted the helmet, I've made a few updates to the costume that I think are worth mentioning.
- I added glowing eyes using moon-shaped lamps from Daiso (a 1$ store in Japan). I fixed the lamps inside the helmet with Velcro tape, which fit perfectly in size
- I added some flexible pipes to the back of the helmet to give an organic feeling and to hide the hood separation. I attached the pipes with Velcro tape has well, which made it easy to remove to put the helmet on and adjust as needed
- Finally, I redid the hand blade with a better quality board and added magnets inside the blade at the elbow position. I also put a matching magnet in the shirt sleeve to keep the blade close to my arm even when extending the arm out.
