Instructables user noveldork’s friend recently decided to cosplay Rem from the anime Re:Zero and noveldork decided to make the character’s morning star weapon for her. She gathered the supplies from her local craft store, using styrofoam cones, a smoothfoam sphere (it’s less porous than styrofoam), a plastic chain, and other basics.
She started by painting the ball and cones in black and silver, respectively, and used a smooth finish on the cones. To attach the spikes/cones to the foam ball, she used wood screws. She says:
I stuck the head of the screw into the cone (remember, it’s styrofoam, it’s gonna make a nice little tunnel), and then pulled the screw out again. I added a dot of hot glue to the screw head and reinserted the screw. Congratulations, you now have an actually harmful spike!
At this point I carved a little bit of foam out of the bottom of the spike so it would lie more flush to the spherical surface (see dotted line). There was not science behind this, it was just eyeballed.
Next, I made sure to carefully plan out where each spike was going to go on the sphere. I am awful at spacing things, so anything you can do to mark your plan is a huge help if you’re like me. A light pencil line will suffice, or even tape. Mark the insert point and then the diameter of the spike.
And when everything is marked, I put a layer of tacky glue on the bottom of the spike (blue highlighter) and stabbed it into the sphere and let it set!
Get complete instructions at Instructables.