How To Mold and Cast Foam Props! 

Watch Adam and Bill Doran make Ringwraith gauntlets out of foam! ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-F48rk7h-GDo.html

Watching this video is so fascinating because it feels like watching two people who have a life time of interviewing experience but have 0 chemistry so they carry the conversation with the correct things to say but it feels like such a lifeless performance.

I make these type of props for film and TV. I wanted to point out that if someone is going to add a stiffener or something to make the handle ridged like in the axe , please do NOT add metal or a chopstick as they mentioned. If you are making these types of props for stunts that is dangerous. The wood can break and then becomes a sharp one that will hurt someone. Same with adding metal. I have found that using a fiberglass rod about 1/4" thick is a great option. To keep it safe I add the little rubber end caps to protect the end of the rod from poking out and hurting someone. They will flex but will not break. Keep them about 1" from each end of the prop. Again to keep it from becoming a stabbing hazard. For a cheaper option, You can find these rods in kite kits. Even at the dollar store places. I found a great way to hold the rod in the center of the object is use thread to suspend it in the middle. Tie one at the top and one at the bottom. Run the thread across the middle of the mold and tie it. It should look like the rod it floating on the threads suspended in space. This way it will not move when the foam expands pushing it to the edge of the part. I hope this helps and keeps your stunt weapons SAFE above all.

I think Norm is doing a great job. While he isn’t the best he represents a lot of viewers who may or may not be educated in these topics. Asking simple questions and explaining certain terms related to the project is extremely easy for me to follow along.

To get a volume for the pour of silicone, just fill the empty mould with rice grains and then tip them out into a measuring cylinder.

Respect the Estwing axe, quality american steel and workmanship and thats coming from a roofer who is in the UK.

"Who are you?" "I am you, but floppier"

Thanks for such a clear overview that answered a lot of questions as I embark on a mold-making & casting adventure!! Sidebar Story: When covid hit, my business of 20 years went straight downhill. Ironic because I design trail maps for Ski Resorts :) So like so many other small businesses, I was essentially shut down. With more time on my hands, I had an idea one night (beers were involved) to carve tikis with a chainsaw - although I'd never used one, sell them locally and use the money to buy lunches for our amazing local Healthcare Workers, Nursing Home staff, homeless shelters, food pantries and other causes of import. My family & I started Tiki Task Force with this crazy idea and it went bananas! Very humbling. At any rate, I'd love to see about creating a mold & casting some of the carvings I've done! This seems like a perfect way to reproduce these pieces, sell them on a bit of a bigger scale and be able to contribute to more & more causes! So thanks again for the insights!

Many people are criticising the interviewer (Norm) for asking questions. Maybe you already know all about the subject matter of the videos; I would question then, why are you watching the video? My experience is that many instructional videos consist of the one person demonstrating how to do whatever it is. Though they MAY be knowledgeable at what they are doing, they too often, don't know about teaching or instructing, so they don't explain what is going on. You'll find their video comments are full of viewers asking questions about aspects that were not properly explained. Norm asks questions that are very relevant and he seems very good at identifying aspectss that need further explanation or reinforcement. This is very useful for viewers, like me, who want to learn from the videos. Instead of the comments being full of people with unanswered questions, his videos comments are from opinionated 'trolls' who have nothing better to do than mock. That behaviour should have been left behind in primary, or grade school. If you know-it-all, why not make your own videos? At least have the grace to 'keep your mouths shut'.

Do more things with Adam, he's the only reason I watch this channel!

Not sure why everyone doesn't like Norm! He just makes sure that the audience knows what is going on, explains things for us. He helped me understand some of the lingo and techniques Frank was using, because for him, its second nature just to do his own thing and not really explain much. Norm is just doing his job, which is hard, because he has to tie the conversation into his questions.

Adam is a busy guy, he can't be in every video. Enjoy the free content you're given. Love seeing Frank work and Norm asks all the right questions that give us all the information we need for the process.

when I watched this about 5 years ago, I said some negative things about the dynamic between these two. I've been through a lot since then; we've all been through a lot. I just rewatched this video, and YT showed me my comment from 5 years ago. I didn't recognize myself anymore. I didn't like what I had written then. people can change. you know what? this is a helpful tutorial, and these guys are doing their best to make this information accessible. good job Norm. good job Frank.

I like what CGI and Green Screen offer, but THIS is the kind of thing that makes me want to make films! Thanks for the very informative video guys!

THIS is the kind of content that keeps me subscribed to Tested. Thanks, guys!

OMG that axe is an Eastwing!!!!! And it looks like it's a 1950's Eastwing!!!!! And Frank just submerged it in silicone goop. I'm so pleased the leather handle wasn't affected! The handle is made of leather strips, layered together, with the tang of the axe going through the middle. The white layers at the front and back of the handle are ivory slices with ebony between them. Absolutely classical and beautiful. I would love to have this axe, to go with the matching hammer I have ;)`

great video. i really enjoyed that you asked detail questions and pointed out things that were getting glossed over. thank you

They came out awesome! Great work guys!

Frank is definitely my favorite tested member

The axe's handle isn't wrapped, it's actually a stack of leather discs. You can see how this is done if you look up "How It's Made Axes".

Yes! These are the kind of videos that first got me into tested. Keep it up, and keep em coming guys!

This is amazing. Looking up how to make some props for Halloween and this is EXACTLY what I needed. Thank you!!

I love Norm's questions. He's always the same with every one and it's great. He knows what he's talking about so well that he also knows how to ask the simple questions that other interviewers wouldn't think to ask. Proof is in Frank's answers when he tries to remind Norm how simple the project can be. Norm and Adam are perfect for the show/channel. However, I'd like to see a video or two about the rest of the Tested staff.

MORE ONE DAY BUILDS 👍

I actually really like the dynamic between norm and frank :)

When you make a video like this show us the de-molding and the open mold.

When he is vacuuming out the pink slime it looks like I should be calling the Ghostbusters and getting Dana Barret out of her apartment.

So happy to see more content like this again on tested!

Great to see building of anything again , this is what drew me to the site in the first place,

9:16 "I made a little bit less than I needed, just in case.." Interesting phrase xD

Very cool. Only downside is the cost of using pourable rubber and these foams for this for hobbyists. The finished hammer turned out great.

The only way could tell the difference between the real and prop hammer was how the weight of the head balanced the rest of it xD it was so good!!

Missed these projects with Frank

Impressive!!! They look very real. & no one gets hurts on set!!!

Dont know why but i feel so relaxed watching these videos

Holy fuck... I started watching this like "How do i know Frank?" - then I realized he was on the first (and 5th) season of Face Off! So awesome seeing how far his career has come

I have never liked this type of mold. I tried it a few times but always resorted back to standard part molds. I find that cutting into the silicone creates too much of a chance of destroying a nice mold, or worse cutting your original piece. Plus....this way takes a LOT of silicone, which is really hard for anyone working on a budget. It makes more sense to me, to use less silicone (enough to smooth undercuts and such) and back the outside up with a jacket of fibreglass or plaster. That way you use less silicone, and you can be guaranteed your silicone will not warp or bend out of shape.

These came out so cool! I didn't expect them to be so floppy! =)

Imagine that everything, EVERYTHING you saw in Lord of The Rings had to be done like this...

That pin trick is brilliant!!!! THANK YOU THANK YOU!

This was so good. Loved it. Thanks for the awesome video tested team.

Everyone has commented about Norman Chan but none of you know that he won't just go if you don't like him he'll still be around because nobody but the people at Tested can make a decision on if he's fired or not and if you are annoyed by him just deal with it and grow up and enjoy the video the props and the insight to making things.

Mad props to these guys.

Norm, The subject matter of your videos are awesome and entertaining to watch. However, your interview style really leaves much to be desired. It might be better to go with more open-ended questions (Why/What/How/Where) instead of simple yes/no questions. Allow your interviewee to form their narrative. Don't form it for them. Aside from that, thank you for these videos!

Yessss thanks for doing this. Working on a few cosplays at the moment and this will help me out a ton.

I love how the silicone looks when it ripples down into the mold

“You have an actor swinging around an Axe make a rubber one”, that’s a lot of effort and work making a rubber actor.

I think Norm is honestly getting better at hosting these videos!

Just what I needed! I want to make some foam 45# plates for the gym!

It looks pretty amazing for a foam copy. The vast majority of people would be totally fooled by either of those but particularly the hammer.

Thank you. I'm making a movie about killer eggs and need rubber egg molds and this really helped me. This is a 100% serious comment

Oh Frank, from Face Off! Cool. Was very surprised to see you back for a second time but it was nice to see you again and get to know you a little better and I was so sorry to hear about your father. Anyway, cool props and terrific paint job.

If this was King Of Random this would have been two weeks worth of content :D

Very good show, clear mastery (on both sides of the camera).

Frank's T-shirt is the best. Paying homage to the greats.

MY GRANDPA HAS THE SAME HATCHET!!! It's in way better condition then the one in the video though. Its all shiny and new looking and doesn't even look 20 or so years old. I was actually really wanting to make a foam coy of it too! Except I was just going to do a two part silicon mold. I was also going to use Flex Foam-It 10 because I prefer 10 more. Fun video to watch!

No ads! Thumbs up just for that!!

Nice vid. Also, great Jack Burton t-shirt!

Damn, the sound of foam core being torn off of silicone is a satisfying thing to hear. :D

Thanks for the video! Please never stop doing this!

I am a fan of Frank. Frank is awesome.

I love his t shirt, the pork chop express. From the classic movie ( big trouble in little China)

I've been waiting for this video for SO LONG. THANK YOU TESTED!!!

How cool is that ! Thank you for sharing this knowledge and video ! Would you use the same technique to mold and cast a piece of flat and round piece of wood carving ?

Those stick pins that you used in your mold to secure things. I know that they're originally for sewing. you could find them in the sewing section at store but my point being is that those little stick pins with the little different colored balls can do some ridiculous damage when muzzle fed into any BB gun. Pump rifle I believe would be the best. Try it sometime.

I don't ever plan on making a prop but damn are these videos entertaining and informative!

Cool to see a different method of molding - but why would this not have been a candidate for a 2-part mold? It seems like, other than time, it would have been better to work with this horizontally and block off the lower half to pour that first layer and avoid bowing sides. Thanks!

Limp Hatchet. That will be the name of my new band. Obviously, we will do mashup covers of Limp Bizkit and Molly Hatchet songs.

I like how Frank reused the foam core from the shop tips video where showed off different nozzles for spray paint. :-D

Franks shirts in this video are the best.

Hit norm with the hero copy!

That floppy hatchet is so sad lol. It turned out at least looking super cool though! Really do love these videos. I don't agree with a lot these comments criticizing Norm and I hope he knows we love him and love Tested and even the criticism probably is coming from a good place

Very cool! I like the Pork-Chop Express shirt!

WOW THAT HAMMER LOOKS REAL GREAT JOB ! SO I SUBSCRIBED 👍👍👍

These are my favorite videos.

Have you ever had any problems with damaging the hero props? I'm thinking of molding some cosplay props in the future, but with not having any experience damaging the hero props worries me a bit. Any help would be much appreciated. Thanks and I love the videos, keep em coming.

That zigzag-cut strategy is so genius.

Beautifully explained..

Wooooo! I'm glad they painted old floppy there. It's hilarious.

Dont know why but Frank really looks like such a nice guy!

when I made molds for small object I used a pvc pipe, split up, kept together with ducktape, its very simple and once I use the mold the pvc pipe is good to keep it intact.

That Estwing hatchet's handle isn't wrapped but made of a number of stacked disks of thick leather.

love norm asking questions

I don't wanna be disrescpectful towards teh way Tested makes videos, but I feel Norm being in all these videos is a little awkward. I understand he represents the audience by asking questions, and most times I appreciate it. But sometimes I feel solo projects are good - take Adams projects, he explains what he's doing on his own as he does it. I reckon Frank should do this from time to time. Again, no hate, love the vids, just maybe some advice

Pretty brilliant how they do this, great vid, thanks!

wow. That is amazing. Couldn't tell which was real and which was a prop.

I would love to do this kind of thing, but I can't afford the nearly $200 of silicone they used to make 2 small molds!

What kind of paint would you use to paint the foam, and is there a way to dye polyfoam if you wanted one full color?

Seems like a box with adjustable corkscrew sides would really help with the bowing on different sized projects.

I think i need a toolbox full of foam tools to mess with people now.

WOW.. incredible good walkthrough :) thanks for this. thank you TESTED..

THATS SOME NICE LOOKING GOO

This is one hell of a good video. Thanks guys!

such a great trick this one with the pins! cheers!

How do you keep the paint from flaking or coming apart with use, or is that not an issue?

Ahh the Estwing camp hatchet. I love mine!

thanks for mentioning the type of silicone. was wondering about all the materials and stuff

ohhh this really makes me want to make a mold/prop

So much flavour its so tender

This stuff looks so satisfying :)