Hero prop build - the 'Evil Dead' chainsaw

An entirely from scratch creation - that works!

It's official - J Robert Clark - Science-Fiction-Create is on YouTube. Watch the premiere November 12th at 8 PM ET/5 PM PT. For the first episode - my Evil Dead chainsaw build!

A link to the official trailer is at the bottom of this story - but please read through first. Thanks for being here. I appreciate you. ~JRC

Just in time for Halloween - the chainsaw from the horror classic The Evil Dead!

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The trusty weapon-of-choice for Ash Williams - hero of The Evil Dead - was a Homelite XL12 chainsaw.

To many, it’s as recognizable as Luke Skywalker's lightsaber.

The saw’s modified housing fit where Ash's right hand once was. He used this very saw to lop off his own paw before the evil that infected it took hold. Gruesome, I know. But it's a fantastic story coupled with exceptional effects.

The Evil Dead chainsaw is a heavily customized Homelite, as any fan will attest. My build is a take on this beloved power ax. Not merely for the display shelf - my eight-year-old son will be donning this working prop for Halloween 2020.

Yes, I said working. That's the kind of fan, maker, and dad I am, baby.

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Not familiar with anything Evil Dead? And wondering why I called you "baby?" Not to worry.

But do pay attention to the saw.

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My version is a wood, plastic, metal, and paint creation with a 12V motor that spins the chain. I used a bicycle's instead of a real chainsaw chain (for safety). But it looks scary enough and makes a nice whirring rattle as it spins.

There's a toggle switch on top to turn it on, and a trigger switch (from a power drill) inside that regulates the chain speed. The user inserts his or her hand to wear it and make it go. Inside I've also included a microprocessor and some other gadgetry. I'll hook these up later for sound effects upgrades and maybe even exhaust smoke.

Early in the process. Note the cardboard model behind me - always a good first step.

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The body is plywood. I learned to bend it to mimic a real chainsaw's curves. The build took a lot of new-to-me fabrication skills like this. I machined plastic to create the pull start and scored aluminum to shape it into the top handle. And I figured out how to bend PVC pipe - without kinks - for the side bar grip.

Primed and ready?

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This latter technique - bending PVC - was loads of fun. The process requires heating sand to an ungodly hot temperature. Then one must pour it into the pipe - without getting hurt. In seconds, the rigid tube transforms into a floppy noodle.

It took me a couple of tries to get the bend right - and I burned some things in the process. I also spilled a lot of sand and ruined a pot. But the final result is spot-on, so all-in-all, I'd say worth it.

Some assembly required. Recognize the PVC pipe?

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All the hardware is functional. The visible bolts hold the saw together and allow for easy service and mods. And the chain bar - also fabricated from wood - attaches and tightens like a real chainsaw's.

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More on my inspiration.

The brainchild of Sam Raimi, The Evil Dead (1981), shocked the world with its over-the-top premise. Evil lurks all around and can be unleashed by reading passages from an ancient text - the Necronomicon, or “Book of the Dead.”

Ash, girlfriend, sister, and buddy go camping in a secluded cabin in the woods (sounds cliché now - but this plot basically started with Evil Dead). There, in the cabin, our protagonist and friends find the book and mistakenly read from it. Hell is turned loose on the world - with bloody dismemberment to follow.

Banned in parts of Europe, The Evil Dead broke the mold - in theme and execution - despite a shoestring budget. Afterward, Raimi rose to A-list status - only when critics finally recognized his artistic genius. But fans knew right away that Evil Dead was something special. And its star, Bruce Campbell as Ash, became an instant horror hero.

If Jamie Lee Curtis (from 1978's Halloween) is the official "scream queen," then Campbell is the uncontested king.

"Hail to the king, baby." ~Ashley J. Williams

Suffice it to say, The Evil Dead changed movies forever. It spawned two sequels - Evil Dead 2 and Army of Darkness - both celebrated by critics and moviegoers alike. Several comics and a successful TV series followed. To this day, Evil Dead maintains a dedicated cult following. There’s even a documentary.

With all this fandom, it’s no surprise to see a be-sawed Ash Williams roaming the streets every Halloween. But it's rare to see a homebuilt, working prop like this one.

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Back to the build.

Once constructed, I had to paint and finish it. First, I sanded and smoothed the exterior, using filler and primer to form a nice base. I then applied three coats of latex enamel. After several long nights working and refining, the completed saw was ready.

Almost.

This needs a little something extra…maybe some dirt? Oil? Blood?

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To the casual observer, it appeared to be a real chainsaw - a brand new real chainsaw, that is.

Some weathering was in order.

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The most fun I had with this build was in the last two hours. I finished the prop using tempera & acrylic paint, brushes, metallic Sharpies, and some damp rags. A little “artistic weathering” went a long way towards making this prop hero worthy.

All said and done, my Evil Dead chainsaw looks like it sawed many trees in its first life. And battled evil in droves, its second.

It’s a grimy, bloody mess. And it’s finally done.

That looks good as used. Well used.

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So what do you think? Excited to see more? Want to watch it buzz?!

If so, you’re in luck.

A tell-all "how I made it" premieres next month on YouTube!

I filmed the build from start to finish - all 40 hours of it. Right now I am editing this into a thirty-minute episode for my new channel. The self-titled show - J Robert Cark - Science-Fiction-Create - will debut November 12th.

As the main feature, I will share this and other builds I create in the lab (my shop).

The show will be part how-to - I'll relate tips and tricks to help makers up their game. But more so, Science-Fiction-Create will be a "why not" - as in why not build an elaborate, working chainsaw prop for my son this Halloween?!

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You don't have to be a horror or sci-fi fan to enjoy Science-Fiction-Create. And you don't even have to be a maker. My channel combines many things of interest - science, movie magic, and lots of creating. Besides film-inspired props, I also make contraptions for my lab like jigs, storage, and other DIY stuff. I'll share these along with tooltips, personal anecdotes, and musings on science and life.

Best of all, with Science-Fiction-Create, I'm always learning. My making pushes the limits of what I can do, and I'm often experimenting with new techniques and tools. These I must figure out on the fly - and the mistakes as-well-as triumphs I capture - and share - as they happen.

The goal is to teach, entertain, and - most of all - have fun.

Please join me this November 12th at 8 PM ET/5 PM PT on YouTube. It'll be groovy, I swear.

Until then, Happy Halloween, baby.

Science. Fiction. Create.

JRC