Corner / Entrance Pillars

Build a prop pillar to accent corners, provide an entrance gate. This will show you how to build a faux pillar.

Tools and Supplies

With the 4x8 foot sheet of 1 inch Polystyrene, in the 8 foot direction, measure and mark the desired height of the pillar.
Using a straight edge and a utility knife, cut the foam on the measured marks. Make sure to slice as deep as you can.
Drag the foam to the end of the table placing the score mark over the edge of the table and snap the foam.
In the 4 foot direction of the foam board, measure and mark 12 inch, 24 inch, and 36 inch distances. Each mark will be the edge of the pillar panel.
Using a straight edge and a utility knife, cut the foam on the measured marks. Make sure to slice as deep as you can.
Drag the foam to the end of the table placing the score mark over the edge of the table and snap the foam.
If you have tongue and groove foam board, using the utility knife, slice off the tongue from the edge of the foam.
At this point you should have 4 pieces of foam 12 inches wide and however tall of pillar you are building.
Using a knife or table saw, cut 45 degree angles on the long side of every panel. The outside of the panel should be 12 inches and the narrow part of the panel should be a bit over 9 inches.
Panels are ready for Assembly

Using the cutoff from the 1 inch foam board, measure a 13 inch by 13 inch square.
Using a straight edge and a utility knife, cut the foam on the measured marks. Make sure to slice as deep as you can.
Drag the foam to the end of the table placing the score mark over the edge of the table and snap the foam.
With a 2 inch thick piece of foam board, measure a 15 inch by 15 inch square.
Using a straight edge and a utility knife, cut the foam on the measured marks. Make sure to slice as deep as you can. A serrated knife also works well to cut deep in thicker foam.
Drag the foam to the end of the table placing the score mark over the edge of the table and snap the foam.
Cap Pieces are ready for Assembly

(Qty 4) Cut the 2x2 down to the length of the height of the pillar panels.
(Qty 1) Cut the 2x6 down to 10 inches in length.
(Qty 0-4) Cut the 1x4 down to 2 inches shorter than the length of the pillar panels. You will need one of these for every side you will need to mount things to.

Lets put together everything we have prepared.

For reference the narrow side of the foam is the inside surface of the pillar.

Using the spray foam as a glue, apply 2 strips of spray foam at the edge of the long edge of the foam.
Take two 2 by 2’s and place them on the spray foam at the edge.
Flip the foam and 2 by 2’s over, making sure to keep the 2 by 2’s in the same place.
Line up the 2 by 2’s edge with the edge of the angle.
Secure the foam to the 2 by 2’s with 1 and 1/4 inch screws. Make sure to counter sink the screws in the foam by 1/4 inch. Use three screws in each board.
Flip the foam where the boards are on the top again.
Taking another piece of foam board.
Align the edge of the foam with the foam we attached the boards to.
Apply a line of spray foam.
Place the panel at a 90 degree to the first piece of foam, matching the 45 degree angles together.
Screw in place with 1 and 1/4 inch screws.
Repeat for the other side.

Using 1 and 1/4 inch screws, attach the 10 inch 2 by 6 between the two side panels at what will be the top of the pillar.
Make sure the board is flush with the edge of the foam.
This will give a surface to attach things to on the top of the pillar through the foam.
To give a stable surface to attach things to the side of the pillars, use the 1 by 4 boards.
Applying spray foam as glue place your 1 by 4’s on the desired sides and attach through the foam using 1 and 1/4 inch screws.
This build is a corner pillar so I am placing the boards on 2 sides next to each other.
Apply the spray foam around the board to add support and hold the boards in place.

Using the same assembly process as the first panel we built...
1. Apply spray foam for glue
2. Place the two 2 by 2 boards at the edges
3. Flip and screw into place with 1 and 1/4 inch screws
With the 3 sided pillar stood on end, attach the pre-assembled side using 1 and 1/4 inch screws

Flip the pillar where the 10 inch board is on the top, apply spray foam.
Take the 1 inch thick, 13 by 13 foam square and center on the top of the pillar.
Apply spray foam on the top of the 13 by 13 square.
Place the 2 inch thick, 15 by 15 foam square on top and center.
Drive 2 and 1/2 screws through the 2 layers of foam into the 2 by 2 lumber used to attach the side panels together. Do this for all 4 corners. The screws will be driven about 1 inch below the foam surface.

Last updated 7 months ago