Cowl 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



2mm craft foam

Amount: 1 sheet of size 8.5” x 11” or larger.

1 sheet of 2mm foam will be more than enough as you will only use them for the inside of the ears.

3mm (1/8”) Minicell Closed Cell foam

Amount: 1 sheet at 24” x 36”

One sheet at 24” x 36” should be enough but I recommend getting two sheets, just in case you need to re-cut some pieces.

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 of foam.

Fabric (optional)

If you’re looking to add the side detail cutout on your cowl and would like to use the same fabric I used, pick up:

Yaya Han’s Carbon Fiber Black Fabric at Joann’s

If you have a local Joann’s fabric store, they will likely carry it, too.

½ a yard will be more than enough for this project. If you aren’t in any rush and you would really like to use this particular fabric, I would recommend waiting for a sale or coupons that can save you a lot of money as Joann’s offers some sort of deal pretty regularly.


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.

  • Plasti Dip – Black

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


Elastic is used for the chin strap. You’ll need something flexible like this. Foam flexes and bends well but it does not stretch a lot.

1” elastic on Amazon