Project
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Ash's Chainsaw - Evil Dead
Year
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2023
Category
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Industrial Designer
Prop Maker
Cosplay
Special Effects
Synopsis
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Recreation of the iconic Chainsaw from the Evil Dead series designed as a prop from scratch for cosplay.
Being Faithfull
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Choosing the look
Several versions of the chainsaw were used in the Evil Dead films, and I had to decide which one to recreate. Given its significance, I chose Evil Dead 2 as the primary reference, specifically the earlier version of the chainsaw from the first section of the film, for its slimmer profile and more realistic looking proportions.
Process
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A complicated but rewarding project
Starting from scratch, I designed the chainsaw entirely from reference images, building its proportions based on real chainsaws and ensuring ample space for a hand to fit comfortably inside. The CAD model became highly intricate, comprising numerous sections and layers for assembly. Combining FDM and resin-printed components, I utilized mixed processes to achieve a prop that was both sturdy and visually striking. The blade was laser-cut from acrylic, allowing for etched surfaces that created a realistic yet safe alternative to a metal blade. To complete the build, I fabricated wrist mounts and handles using metal hardware and secured everything with machine screws. Finally, the prop was painted and weathered with an ingenious method devised by my partner, who mixed sawdust, PVA glue, and paint into a greasy paste. This was smeared into crevices and across the saw, adding a gritty, well-worn appearance.