Halloween Arch

Directions

1. Sketch your design on paper to visualize the final arch.
2. Purchase a block of 2-inch thick styrofoam from a local hardware retailer.
3. Carve brick patterns into the foam using a plunge router bit.
4. Smooth the bottom edges of the solid sections with the router to mimic poured concrete.
5. Shape decorative bones using a Dremel rotary tool.
6. Test your paint choices on a small foam scrap to check the finish.
7. Apply solvent-based paint to the mortar lines, allowing it to slightly dissolve the foam for a weathered texture.
8. Construct a simple frame using a 2x4 board, then attach the foam block with wood glue and screws.
9. Secure the upper arch sections with wire while the adhesive sets.
10. Fill any gaps or seams with wood putty.
11. Paint the mortar lines black using one pint of water-based paint, then mask the areas to protect them.
12. Apply a base coat of gray water-based latex paint, using one quart.
13. Add depth and age by spraying matte black paint over the surface.
14. Finish with two coats of stone-textured paint, requiring two cans.
15. Note that the water-based latex layer shields the foam from damage when applying solvent-based paints later.
16. Tuck shredded plastic bags behind the structure to conceal the wooden frame and any gaps against the wall.
17. Attach purchased decorations, including skulls, chains, and a 'Beware!' sign, to complete the look.