How to Build a Modular Arrowhead

A how-to guide, dictated by Squire Emrys ElderBranch, edited by Lord Bova

Welcome to Squire Emrys' Modular Arrowhead tutorial. While there are many different schools of thought and builds on modular arrowheads this is uniquely suited for Emry's needs. Please not that while this tutorial is comprehensive, it is not exhaustive and there may be problems you face on your build that will be unique. For any and all questions concerning weapon builds, tips, and tricks please reach out to your community!


  • - 4lb cross-linked polyethylene foam

  • - Measuring compass

  • - Ruler

  • - Knife

  • - PVC pipe (3/8th inch)

  • - DAP liquid cement

  • - Penny (or metal disc)

  • - Mounted dremel

  • - Junior tennis balls (foam)

  • - Tape (grip or hockey tape)


  • - Hot knife table

  • - Plastidip

  • - Cloth

1- Using 4lb cross-linked polyethylene foam use a compass to make a 2.5 inch circle.

2- Using a sharp knife (in this case an old kitchen knife) cut this circle out as close as your can to your circle. Here we’re using a hot knife table to finely shave down your cylinder but any bladed edge will do!

3- Using that table (or edge) angle down a 20 degree edge around your cylinder, giving it a tapered shape from your center. Slowly shaving it down into a cone.

4- Find the center of your cone. Here you’ll drill a 3/8th inch hole to place your PVC pipe core. For this we’re using a mounted dremel. You’ll want this pipe core to be 3/8th wide and 2.5 inches or longer.

5- At the face of your cone (the wider end) drill a wider slot out to place your penny (or metal disc). This will ensure that your arrow shaft wont pierce through foam and injure other players. Center your cone and dremel down about enough for your penny. The penny will sit into this engraving and should be pretty tight. You may have to move the foam around a little but once it’s in it should fit snuggly. 6- Using an adhesive such as liquid cement lightly cover your PVC pipe piece. Wait a minute while the adhesive becomes tacky. Next you’ll push the PVC into your drilled hole in from the front of the cone and put your penny in over it.

7- Your first arrowhead base is finished! Next lets take a look at building a cushioned tip! I’m modeling mine after some hands-on research from Michael Halcon Gustafson. He was the first to use this way of building and I adapted it for my builds!

The best arrowheads can last years! (Mine have lasted 4+ years before they finally failed.) I use a build based on junior tennis balls. These are already streamline shaped and fly like bullets!

You can pick these balls up at any sporting goods store. I use Dick’s Sporting Goods version which is “Slazenger” or “Prince play and stay”.

8- Lets start by cutting your tennis ball in half using a knife (or if you have one, the hot knife to make a cleaner cut).

9- Using a ruler and the handy compass, find the middle of your circle and make a 2.5 inch wide (diameter) circle around this point.

10- Using the hot knife or blade cut off the excess surrounding your 2.5 inch circle.

11- Next we’ll need some padding between this tip and your base. To add your “buffer” to the base and tip you can layer two quarter pieces of 4lb foam.

Glue these down and then shave with a hot knife or knife to keep your arrow streamlined. Alternatively, you can use a single piece of one inch thick 4lb foam as a buffer between the base and tip as well.

Both of these separators adds weight to the arrow head or lowers to balance the arrow shaft.

12- Now you’re finished with the foam-craft! You can cover the tip of your arrow with cloth and tape the sides or Plastidip the sides depending on your preference!

And there you go, a modular arrowhead ready to be mounted on an arrow shaft or crossbow bolt! Got any questions on how to check a missile head to make sure your arrows are safe and ready to fire? Check out our handy equipment checking guide here.

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