Carving Faux Beams from Large Blocks of Styrofoam

You may like ceiling beams in your home, but if they are not built into the original construction you may need to settle for faux beams. With a little practice, some dependable instructions, a few blocks of Styrofoam, and some simple tools and materials; you can make these fax beams look almost as real wood beams.

Step 1 – Creating Your Beam Shapes

Decide how wide and deep you'll want your faux beams. Use your measuring tape to measure on your Styrofoam blocks the dimensions you've chosen for your faux beams. Lay your Styrofoam block on a clean surface, use a carpenter’s square to make a straight line you'll use to cut the beam shape from the block. Then, use a fine-tooth saw to cut out your beam from the block.

Step 2 - Creating Faux Wood Grain

Some woods, such as walnut, have prominent and distinct grains. In other wood like mahogany, you'll find a grain that is finer and smoother. If you want your faux beams to look real, you'll want to create faux grain on them. Examine a few sample pieces of various woods. Study their grain patterns and decide which patterns you prefer on your beams. Using a notebook and pencil, draft some patterns until you're satisfied with one you've created. Try to include characteristics you have seen in your wood samples. These might include knots, converging lines, waving lines, etc.

Step 3 – Draw Your Pattern on Your Styrofoam Beam

Use a permanent marker to draw the wood grain pattern you've chosen to duplicate on your faux beam. Be sure to draw the grain patterns, including the way each line in the pattern continues onto each side of the wood block. To be sure your grain pattern looks real, step back a few feet to examine your work.

Step 4 – Carving Your Faux Beams

Use a rotary tool with a shaping stone bit and begin carving your beam's edges, slightly rounding them to resemble the edges of a wood beam. Try to recreate the naturally uneven edges of wood beams. When finished carving he edges, begin creating the grain lines by cutting them with your rotary tool. These lines, if they are to match those of walnut wood, will be about 1/8 inch deep.

Step 5 – Finishing Up

When finished carving, begin using a fine grit sandpaper (150 grit) and sand until you've smoothed out any rough surfaces or edges. Remove any dust or debris with a soft brush or shop vacuum. Apply your paint, using a variety of brushes with soft bristles. Use wider brushes for broader paint areas, smaller brushes for lines. Follow the colors you see in your wood samples. Usually, you'll need to use at least four shades of the same color. Cover your beam with the primary color, usually a darker brown. When this paint has dried, you will need to work in the lines with lighter shades or colors.