Uploaded November 2025 | Updated September 2026, 2 weeks ago

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How to Make Chainsaw Man Cosplay helmet with Free EVA Foam PDF Templates! In this Part 1 video I will go over all of the steps I took to create this Chainsaw Man / Denji Cosplay and by downloading the free PDF templates from my site you can build it right along with me. This Chainsaw Man helmet prop is made almost entirely out of EVA HD Foam and because of that it weighs in at an amazing 1 pound 10 ounces! In this Part 1 video I go through all of the fabrication steps needed to create the cosplay helmet. In Part 2 I will cover the acrylic painting and weathering processes including epoxy gore. This Chainsaw Man cosplay is based off of the manga and the Anime PV trailer. I took some liberties myself with the back of the head because it is never fully shown in the trailer and varies panel to panel in the manga. Because of that some details might not be 100% but it's definitely good enough for cosplay and worse case you can make up your own details.

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