Denji is the main character, in both the Chainsaw Man manga and anime series and the Public Safety Saga.
He receives his father’s debts from the Yakuza as a young boy. In an effort to pay off his debt, he becomes a Devil Hunter for the Yakuza after meeting Pochita. He dies when the Yakuza, led by a devil, betray him, and Pochita becomes his heart. By pulling a cord on his chest, he now takes on the role of Chainsaw Man. He became a Public Safety Devil Hunter after meeting Makima.
Table of Contents
Parts of Denji Cosplay Costume from Amazon
To make Denji Cosplay Costume from Amazon you will need :
Click on the links if you want to buy directly the parts to make the costume from amazon.
Materials needed to create Denji Cosplay Costume :
Mask Template ( download )
Arm Template ( download )
HD-Foam – http://bit.ly/2NECyrU
HD-Foam Dowels – http://bit.ly/375zTPs
Foam Clay – http://bit.ly/2uR9pD5
My favorite Mechanical pencil – https://bit.ly/3eUNxvP
PVC Board – https://amzn.to/3sBjXlK
Wood Burner – https://bit.ly/3AwpHgJ
Wood Dowels / PVC Pipes – Lowe’s Plasti Dip – https://bit.ly/3eZYzOk
Flexbond – http://bit.ly/2TDVDOM
Super Glue – https://bit.ly/38zbAgn
Contact Cement – https://bit.ly/34dyQ0Q
Hot Glue Gun – https://bit.ly/2Fey6iB
Cutting Mat – https://bit.ly/2LJuo03
Heat Gun – https://bit.ly/3aBioIQ
Large Utility Knife – https://bit.ly/3bAbq6M
Small Utility Knife – https://bit.ly/3413rNI
Hobby Knife – https://bit.ly/2wQFOLn
Dremel – https://bit.ly/3fOCXmx
Dremel Flex Shaft – https://bit.ly/31AJ09j
Liquitex Heavy Body Acrylics – http://bit.ly/2Sce8HK
1″ Mop Brush – http://bit.ly/3f0Xbic
Filbert Brush – http://bit.ly/2GQfVwK
Liner Brush – http://bit.ly/2GQfVwK
More Brushes – http://bit.ly/2GQfVwK
How to Make a Denji Costume DIY – Start with the Mask
Let’s start by finding some reference pictures. We have found some for you ,so if you like you an use this or find new ones.
How to Make a Denji Costume – Cutting the foam Part 1
Print the template of the mask first.Follow the instructions how to print it in the correct way.
After printing the template pattern ,cut all the pieces from the paper needed to form the helmet .In the pattern each piece has a Letter .Put the pieces of paper on the foam,make a sign with the pen and just cut it.
Lets start with the part A using a 10mm hd foam.
Attention : Along the top edge of part A ,you must cut it out approximately 30 degree angle.This section must have this angle to give a curve to the front of the mask
Referring to the template , Take the part B to the same 10mm foam and cut it 2 times. Just like part A the top must have 30 degree angle but when you get about 2 inches to the bottom you need to transition to 90 degree angle.
Cut out all the slats that are in the part A.
Now that you have part A and B use a heat gun on part B to match the curve of part A.
Use weld wood contact cement to the interior cut seams.Let it dry and press firmly parts A and B
When this 2 parts has been assemble ,they make the front face of the mask.
How to Make a Denji Costume – Cutting the foam Part 2
Take the part C, transfer that onto 10mm foam and cut it out.Mark the part C where is going to align.Apply contact cement to all pieces that will be attached.
Align the outside corner and press the half on to the attach. For the smaller slats just use some superglue.Once you finished 1 side, do the same for the other side.
How to Make a Denji Costume – Cutting the foam Part 3
It time to work on the chainsaw. Take the part D and transfer it on the 6 mm foam.Cut it 2 times.
Optional : If you want to give the chainsaw more stability you can use a metal yard marker.
Bent the rod to shape and trace around it on the inside using a stone bit on dremel.Create a channel on both sides of the foam that will house the rod.Fix it with superglue.
To glue the D pieces together use a 3 mm foam fast spray cement.This will cover all the surface very fast and work great for foam projects.To the edges you can put some superglue just to be shure that everything is attached perfectly.
To make the round part of the chainsaw use a pvc pipe as a rolling pin becouse will make it easy to cut the curves.
Take a scrap piece of 6mm foam ( aprox 2inches x 6 inches ) and glue it to the back of the blade .This is what will hold it to the inside of the front of the mask .
How to Make a Denji Costume – Cutting the foam Part 4
After scrap piece is dry , position it about 1 inch up from the bottom of the mask.
Now glue part B onto the scrap piece , very close to the side of the blade as in the picture ( do it for both sides ).
How to Make a Denji Costume – Cutting the foam Part 5
Lets continue with the other parts. Take part E and F and transfer onto 6 mm foam.
Even here you must cut the tops of part F and the sides of part E into 30 degree angle.So when we glue together this parts ,they will give the shape that we want.
Use a pen to mark approximately where the teeth and gums are going.
How to Make a Denji Costume – Cutting the foam Part 6
To make the teeth i have used 15mm hd foam round dowels . To make the teeth stable and rigid put small pieces of wire in it ( leave a small piece outside becouse it will attached to the other parts ) . To shape the teeth use the scissors and refine it with sanding drum ( if you have a dremel rotary tool ). Do this for all your teeth.You will need around 30 teeth.
Attach all the teeth and if you are happy with the spacing ,add some superglue and fix them into place.
How to Make a Denji Costume – Cutting the foam Part 7
Now cut the part G from 10 mm foam and a bunch of half inch 4 mm strips . This are going to be used for chain links that holds together his jaw
A single stip is glued and then wrapped around part G.
Now transfer part H into 10mm foam . Draw some lines at the lower parts ( as shown in the picture ) and dremel out using a stone bit.By doing this will help to bend at a sharper angle.
Apply some cement and let it dry.After is dry you can glue the parts together to form something like a box shape.
How to Make a Denji Costume – Cutting the foam Part 8
Shaped part H can be glued with part A, B and C and attach it to the back of the mask.
Do the same for the part I as you did for the part H.
Then glue the part I to the back of part H.
How to Make a Denji Costume – Cutting the foam Part 9
Cut some more 15mm round dowels into half inch discs that are going to act as posts for the back of part G.
Becouse of some difference in height the post are be going to be glued into part I and then the half inch 4 mm strips can be glued to the sides of the jaw
How to Make a Denji Costume – Cutting the foam Part 10
Part J is going into 2 inch strip from 6mm foam that will wrap around the back of your head
This can be a viable option if you don’t want to finish all the helmet.
Take part K and and transfer into 6 mm foam. Part K is going to be glued under part I. Its arms are going to wrap around to the front of part H and and front of part I.
Tip:To make it easy mark it with pen and then glue all together.
How to Make a Denji Costume – Cutting the foam Part 11
Transfer part L into 6 mm foam. You will notice that the top section of part L will overlap onto part K. So the top of part L will be glued on the lower of part K. This will give and integrated look and will strengthen the helmet.
Now the inside of part L and K can be glued onto the 2 inch strap that we added earlier.
How to Make a Denji Costume – Cutting the foam Part 12
Transfer the part M into 6 mm foam and just like part J the length will depend on the size of your head ( if necessary adjust the piece ).
Glue the tops of the part M to the undersides of part I and then the back of it can be glued to the part L.
Now the lower 2 parts of part L can be pulled up and glued onto part M.
All these piece overlapping each other will help in the helmet durability .
How to Make a Denji Costume – Cutting the foam Part 13
For all individual chain segments and blades ,we can use 4 mm foam. Part N is traced onto the foam with pencil and then individually cut out.The same process is used for parts O and P.
You will need around 25 each of O and P and a about hundred of N. Now for N i rounded over the four corner and used the drum to make a small divot into the bottom of the piece.
Then all the pieces were held into the heat gun to get light heat seal.
How to Make a Denji Costume – Cutting the foam Part 14
Unlikely a real chain the links don’t connect the blades.The links themselfs are attach to each individual blade. So is just a sandwiching part.
After finishing this process glue each piece to the main saw.
How to Make a Denji Costume – Back Handle Part 15
To fabricate the handle on the top of the back of the head we can use some pvc pipes.The wight of the pvc pipe will help balance the entire helmet. For the measure of pipe you can refer to the template.
To house the pipe on the back of the head, we have to make part Q . First glue 3 pieces of 10 mm foam together. Press the pvc pipe into the foam so you know exactly where its going to go.Smooth the edges and the front. Attach a forstner bit to the drill and drill to the foam to make shure that the pipe sit well ( if you dont have a frostner bit , you can se a rotary tool ).
How to Make a Denji Costume – Back Handle Part 16
Make the 2 rings from the parts R and S. These are going into the pvc pipe but attach the part Q and the back of the helmet.These are additional details that make it look nice.
Mark the part Q on the helmet and glue in the place exactly where the lower part of the handle is going to go.Use the frostner bit or rotary tool to drill to the back of the helmet where the lower part of the pipe is going.
Use again the frostner bit on the side of the helmet and you can see exactly where the pipe elbows are going. Put all the pieces together and glue . Yo must have something like this.
How to Make a Denji Costume – Finishing touches Part 17
Take the part T and trace it from 10 mm foam. We need to reinforce the bottom jaw. Put into place and glue it together.
Now we must attach the bottom jaw with the upper part. Before gluing it ,see if it fits and if you like it. The good of the foam is the if you don’t like, you can change it.
Glue the pieces together when your done.
How to Make a Denji Costume – Finishing touches – Part 18
Now we can attach the part G to the side of the face and stripe down to the lower jaw.
Attach the part U onto part M and attach that also to the lower jaw.For more stability or just to fill the gaps you can attach more strips to the jaw.
To add more detail you can cut out some other part N to add the the stripe of the jaw to make them look like chains.
To break this shapes cut part V out of some foam. Its a subtle difference but is enough to give some interesting details.
How to Make a Denji Costume – Finishing touches – Part 19
Lets star working on part W. This will be an exhaust port on the side of the head. Cut a circle out of 10 mm foam and then glue it to the second one.
Now cut out a circle to match the interior of diameter and mark where the grille will go. This is burn into the foam using a heat tool.
Once it is complete those can be glued inside the cavity of part W.
The part W is complete and we can glue it to the side of the helmet.
To detail this exhaust section cut an additional circle and glue that into the center. Then cut out a small disc out of a 15 mm dowel and glue that in the middle.
How to Make a Denji Costume – Finishing touches – Part 20
Take the part X and cut it out from 10mm foam. Glue the stripe to the front of the exhaust .
Now check your helmet and fill the gaps between parts with any foam. Just to cover all the helmet.
Moving to the part Y , cut this piece 4 times from 6 mm foam.For an additional shape some half roundels are going to be cut and then glued towards the front of this piece. For placement of part Y set the helmet down on the table and then glued that flat to the bottom
Create the part Z by putting some pieces together to represent some kind of machinary.
Check reference pictures if you want to add more detail to the helmet.
The creation of the helmet finishes here .
To do the arm chainsaw’s just follow the same steps of the helmet .That is very much easier than this.
For painting of the helmet , first buy all the necessary items from the list and then slowly start doing it.
I will update further the post about how to paint the helmet.
Denji Cosplay Costume fro Halloween
Denji Story
He is a young man who becomes a devil hunter after merging with his pet devil, Pochita. Denji’s story is one of survival and redemption, as he begins the series as a poor and desperate orphan who is exploited by the Yakuza.
However, after merging with Pochita, Denji gains incredible powers and becomes a valuable asset to the Public Safety Devil Hunters. Throughout the series, Denji struggles to balance his duties as a devil hunter with his desire for a normal life, and must confront his own inner demons in order to protect his friends and loved ones.
