Armor Tutorial

This costume project is made completely out of EVA and craft foam (and some fabric if you so choose). This is a great medium to work with as the materials are relatively inexpensive, easily accessible, and easy to work with.

All painting is done with paint spray cans. So you won’t have to purchase any fancy expensive stuff either.

Here’s a quick rundown of the order of making the armor.


  1. Print and cut out pattern pieces.
  2. Cut out foam pieces using the pattern pieces.
  3. Heat form and shape pieces.
  4. Glue your pieces together.
  5. Paint your armor.


If you are new to working with foam, watch the videos in FOAM 101 BASICS as they cover the essential tools and working with foam basics.

Otherwise, you can get started on the tutorial now.

Project Specific Materials



There are three basic thicknesses you will be using.

3/8” anti-fatigue floor mats on Amazon

Amount: One pack.

6mm (1/4”) L200 foam

Amount: 2 sheets at 24” x 48” or 1 sheet at 48” x 72”

The larger sheet at 48” x 72” is a better deal but will leave you with a lot of extra left over foam.

2mm craft foam

Amount: 1 roll.

1 roll will be more than enough for this project. If you can find sheets locally that are 12” x 18”, 3 sheets at this size should be enough.

Anti-fatigue floor mats can be found at hardware stores like Lowe’s, Home Depot or Harbor Freight. The thinner crafting foams can be found at craft stores like Joann’s Fabric or Michael’s Craft Stores.

Before buying online, check to see if you can source any of this locally. You might find better prices.

You don’t have to use these exact brands or thicknesses of foam. You can use other types and thicknesses if you prefer. But I would recommend staying with similar thicknesses. For example, you could use 3mm foam in place of 2mm foam or 6mm for 3/8” foam. But don’t use 2mm foam for 3/8” foam.


One can of whatever color you choose should be enough for most of your painting. But just in case I would recommend going with paints you can source locally. If you run out while painting, it’s quicker to get another can that way.

Paint Used in Tutorial

You should be able to find most or all of these paints at home improvement stores like Lowe’s or Home Depot.

  • Black Plasti Dip
  • Valspar Color Radiance Paint + Primer Flat Black
  • Valspar Project Perfect Paint + Primer Gloss Rugged Suede
  • DupliColor Bumper Coating Medium Silver
  • DupliColor Bumper Coating Dark Charcoal
  • Rust-oleum Universal Metallic Paint & Primer In One Carbon Mist
  • Rust-oleum Universal Metallic Paint & Primer In One Flat Antique Nickel
  • Rust-oleum Universal Metallic Paint & Primer In One Flat Soft Iron

I would strongly recommend testing and practicing with painting before painting a finished piece.


These items were used as stencils to add texture to the torso base and some of the ab pieces. Proper use is covered in the videos. You should be able to find the plastic canvas at crafts stores like Joann’s Fabrics or Michael’s Crafts store.

Plastic canvas for yarn (used for ab texture).

Plastic canvas on Amazon

Non-slip drawer liner (used for torso base texture).

Non-slip drawer liner on Amazon

Velcro and Straps

Velcro is a cheap and easy way to attach things. You can pick it up at your local fabric store or the link below.

Velcro on