Carving a horse head from XPS foam with a jab saw, scalpel, wire brush, and sandpaper is a subtractive process that moves from aggressive material removal to fine detailing.
Materials and Safety
- Materials: XPS foam block, jab saw, scalpel (with sharp blades), marker, wire brush (stiff bristles), and various grits of sandpaper (coarse, medium, fine).
- Safety: Work in a well-ventilated area, wear a dust mask to avoid inhaling foam particles, and use protective gloves.
Step-by-Step Carving Guide
1. Plan and Mark the Design
- Sketch: Use a marker to draw the top profile and the side profile of the horse head onto the respective faces of the foam block.
2. Rough Shaping with the Jab Saw
- Purpose: The jab saw is your primary tool for removing large, excess sections of foam quickly. It is a relatively aggressive tool for this material.
- Technique: Secure the foam block firmly in a vice or clamp to prevent movement while cutting. Use light, steady strokes and avoid applying too much pressure to prevent the foam from tearing or breaking.
- Process:
- Cut along the marked side profile line to create the basic silhouette of the head and neck.
- Re-attach the removed offcuts (perhaps with tape) to support the block for the next cut, then cut along the top profile line.
- You are now left with a block that has the rough, angular outline of a horse’s head.
3. Initial Shaping with the Wire Brush
- Purpose: The wire brush is used to transition from the angular, sawn shape to the broad, soft curves of the horse’s anatomy (jowls, cheeks, neck).
- Technique: Hold the brush firmly and use long, sweeping strokes. This will tear out chunks and strips of foam, quickly creating general shapes and contours.
4. Refining the Form with the Scalpel
- Purpose: The scalpel is for more controlled material removal and establishing key features.
- Technique: Use a fresh, sharp scalpel blade for clean cuts. Use multiple, shallow passes rather than one deep cut to maintain control and avoid tearing the foam.
- Process:
- Refine the transitions between the areas shaped by the wire brush.
- Carve in the basic anatomical features like the eye sockets, the line of the mouth, and the contours of the jaw and muzzle.
- Carefully carve the form of the ears, tapering them to a point.
5. Detailing and Smoothing with Sandpaper
- Purpose: Sandpaper refines the surface and blends all the shapes together for a smooth finish.
- Technique: Start with a coarse grit (around 60 or 80) to remove prominent tool marks. Move to a medium grit (120) and finally a fine grit to achieve a smooth, professional finish. A sanding block or a piece of dowel (for curved areas) can aid control.
6. Final Touches
- Review: Inspect your sculpture from all angles to check for symmetry and detail.
- Clean: Remove all foam dust with a damp cloth or vacuum.
- Finish: Seal the foam with a protective coating like Mod Podge or a foam-safe primer before painting with acrylics.