Foam Chainsaw Prop
Need a chainsaw for your cosplay but the convention won't allow real chainsaws? No problem, just recreate it in foam.
This chainsaw prop, weighing only about two pounds, consists mostly of hand-cut EVA foam. The guide bar (the part the chain wraps around) is a piece of 1/8" thick foamed PVC. The front handle is a length of PVC pipe that has been heated and bent into shape.
The prop includes some real screws and bolts for realism, in addition to some bottle caps and other found parts. The highly weathered paint job simulates chipped paint, rust, and leaking oil.