Even though I look at tons of cosplay stuff, I sometimes forget that anything can be fashioned from PVC foam (Sintra is one option). Instructables user Goombah Squad used the material to make some cool Battlestar Galactica guns to go with his costume. After he purchased blueprints from another builder, he used the foam to piece together the gun. After that it was all abut the shaping. Here’s the steps he took to get the gun just right:
I use a Dremel with a sanding bit for 80% of the work. The remaining 20% is a variety of needle files, various grits of sandpaper, or the occasional grinding and engraving bit. I started by shaping and gluing the main frame of the gun. Once everything was how it needed to be, other pieces were added: grips, various rails along the side of the barrel. The two halves of the slide action were each crafted separately. So was the grenade launcher attachment.
Once everything’s shaped, break out your Bondo. Bondo is an automotive filler typically used to fill in car dents and dings but as you’ll find, it’s widely used in propmaking. Anywhere you see unsightly seems or low areas, mix up some Bondo. Wait about 20 mins for it to cure when it becomes unworkable.
Read more at Instructables.