DIY Crown from Foam Core

My husband, a master with foam core, made this crown and the sword to go with Bambino’s King Arthur costume. Instructions for the sword and the rest of the costume are found separately.

This crown design could be changed and adapted in dozens of ways, but creating a crown out of foam core is easy and very inexpensive. It just takes some time.

Step 1: Make the Pattern

Draw a repeating crown pattern of your choice on a piece of foam core making sure it will be long enough to fit your child’s head.

Cut it out.

Step 2: Cut the Inside Ring

Cut another strip of foam core the same length to serve as the inside ring.

Step 3: Make Kerf Cuts

Using a craft knife make kerf cuts about every 1/2” along the inside ring piece. If you cut through the paper on only one side, the foam core will bend. Don’t cut all the way through both pieces of paper.

Step 4: Curve the Crown

Using a craft knife score the back side of the crown about every 1/2”. If you cut through the paper on only one side, the foam core will bend. On this piece, make a second series of cute and remove a small wedge of foam at each incision.

Step 5: Create the Dome

Bend the inside ring into an oval the right size. Secure it with packing tape.

Trace the inside ring onto another piece of foam core.

Cut a rectangle of foam core that is slightly larger than the inside ring.

Make cuts from corner to corner of the rectangle. Do not cut all the way through the foam core.

Step 6: Fasten the dome & Inner Ring

Cut along the traced oval. Completely remove one wedge from the oval.

Bring the two edges together where the wedge was removed and secure with packing tape. The center of the crown will pop up and the oval will make a dome shape.

Secure to the inner ring with packing tape.

Step 7: Cover the Dome

Cover the dome with aluminum tape.

Step 8: Attach the Crown Ring

Glue the crown ring to the inner ring.

Paint the crown ring and allow it to dry.

Step 9: Embellish

Add jewels using hot glue once the paint has dried.