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.
- Print and cut out pattern pieces.
- Cut out foam pieces using the pattern pieces.
- Heat form and shape pieces.
- Glue your pieces together.
- Paint your armor.
NEW TO WORKING WITH FOAM?
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.
Project Specific Materials
There are three basic thicknesses you will be using.
Amount: 2 sheets at 24” x 48”
Amount: 1 sheet 8.5”x11” or larger.
1 sheet will be more than enough for this project. If you can find sheets locally that are 12” x 18”, 1 sheet at this size should be enough.
You can use anti-fatigue floor mat foam for some of the patterns that are recommended to be cut out of 6mm foam if you prefer but it is not necessary.
Amount: One pack.
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 this paint at home improvement stores like Lowe’s or Home Depot or possibly an automotive store.
- Valspar Project Perfect Paint and Primer – Flat Black
- Plasti-Dip – Black
I would strongly recommend testing and practicing with painting before painting a finished piece.
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.