We were commissioned by Desjardins to create a giant soccer cleat for the AFC Toronto home opener. The purpose was to give fans a place to write encouraging messages to the team.
After some brainstorming, we landed on a 7 ft white soccer cleat mounted to a movable base. There are many ways to approach a build like this, but we were happy with how it came together.
The shoe started as a generic soccer cleat that was custom 3D modelled from scratch, including stitching details, laces, and studs on the bottom. The model was then sliced and CNC cut from foam for accuracy. Hundreds of foam slices were assembled with adhesive and aligned using pre-planned dowels.
A brushable hard coat was applied in multiple layers to create a durable exterior. The next stage involved filling, patching, and sanding until a smooth surface was achieved. A combination of fillers, epoxies, and finishing techniques were used throughout the process. Threaded rods were installed into the cleat studs to create a secure connection to the base.
The shoe was finished with primer, white paint, and a 2K automotive clear coat for a glossy finish.
The base was built from plywood and sanded smooth. Handles were incorporated to make it easier for staff to move around the stadium while keeping the wheel system hidden from view. The base was painted with a weather resistant finish and covered with faux grass. Removable styrene graphics were added to make transportation and storage easier. A protective top cover was also built to keep the cleat safe while in storage.
This project was a fun combination of fabrication, engineering, and fan engagement. Now all that's left is to build the matching shoe. One day!
