Step 5: Add the trim

This is where your own creativity comes into play. Besides looking good, the thing your trim is best at is covering up glue lines. When adding the trim, try to glue the edges, but use a small bead of hot glue to reduce glue seepage from the edges (a little can be okay though, and could be incorporated into the weathering effect later).

The first thing I did was cut out 7/8-inch thick strips of black 3mm craft foam. I carefully measured around the helm, and added roughly an inch to each length to account for error. Cutting these is easiest with a rotary cutting tool, cutting board and straight edge, but it can be done with a hobby knife rather than rotary cutting tool. A big paper cutter would probably be even better.

You will find times when you need to decide whether to cut the segment to fit or to overlap. From my experience so far, I would recommend taking the extra time to cut the strip that would overlap another, because in my opinion I think it looks a bit better. I recommend gluing the strips where you need them first, then carefully cutting them on the helm itself to fit. The heat from the hot glue tends to warm up the foam to a point where it stretches easily, and your dimensions will not be as accurate as they were on the cutting board.

 Using the stencil from step 4, I cut a second face plate (black, pictured above) out of 3mm craft foam. This piece may not be necessary, but I liked the way it looked at the time. Be sure to use a lot of tape, and follow the same procedure as with the thick face plate. I cut the eyes out slightly larger so that they showed some of the material behind it. Glue the black face plate on with hot glue being careful to line everything up properly.

Super helpful!! I've been making iron man parts out of random materials for sometime and getting frustrated with weird unexpected "off-material/brand" problems. This saved me from all that!
<p>Dude this is awesome! I am gonna have to try and make something like this, your tutorial will definitely help and I am going to look at the cosplay forum. I am thinking of using EVA foam because thats what everyone has recomeended, have you ordered from univfoam.com before, I found some there and it seems like a good deal.</p>
My project was a success because of your post and I wanted to let you know that. :) Keep posting, I would like to see what you can come up with. I recommend a wagon and horse prop or maybe a building prop so we can learn how to make scenes. The more reusable, the better. I spray painted mine and let the fumes wear off on a nice day then I sealed it. It was dry within the next 2 hours (roughly) and then I put a clear sealant on top of my metallic paint to make it resemble the looks of metal even more.
Awesome! I'm really happy to hear that. I dropped the ball on getting a lot of these projects done when I moved from college to a full-time job, but hopefully I'll be able to get some more instructables posted some time in the near future. Thanks for taking the time to let me know; it's encouraging to hear that my work has inspired others.
I wanted to say thank you for posting this-- I've made my own armor with it! &lt;3 <br>http://imageshack.us/photo/my-images/571/dsc0750j.jpg/
Sweet job. I have made a pretty nice papier mache helm, but I think I am going to try an EVA foam one to see how those results go. I am hoping the foam will create a little smoother to work with initially.
Where did you get the horns? I was planning to make a sinister viking type helmet with similar horns but have no idea where to find them.
very nice!
Fantastic instructable!
i used to wear a helmet like that, but then i took an arrow to the knee!
Not the heel, Mr. Achiles?
.........KRII LUN AUS!
EVA foam is easily one of the best costume making materials!
Did anyone figure out where to get the card board peice he found in the trash?
It is a sonotube. You can get one at any home improvement place. It is used as a form for concrete poured-in-place pillars.
Dude, this is sweet. I am totally going to make one or two of these.<br><br><br>FUS RO DAH!
Is this airsoft proof
Just wanted to add my two cents when working with Mod Podge :3 <br> <br>I make gryphon costumes for kicks and the beaks are made in a similar way as your helm. I apply Mod Podge full strength over the papier mache beak forms and smooth it with my hands. Once your base coat is on thick enough to even out most of the bumps you can smooth it down even further by waiting until your most recent layer of podge is tacky and going over it with wet fingertips. In my experience I find glue takes too many coats and since Mod Podge is a sealer in itself don't prime my base forms with anything else first. <br> <br>I'll be trying this with EVA foam shortly; I've always wanted a warcraft Paladin's tier 2 armor despite never actually having played one :P Thanks for the ideas!
No problem! Thanks for the input, I'm always happy to learn new ways of doing things
Oh wow, this is great! I can't wait to see your body armor tutorial, I have a set that I want to make that I think your technique looks PERFECT for! I've little experience with prop armor, so I'm always excited when I see something promising. :)
Thank you! The body armor itself is still in the works, so the instructable is going to be a while, but so far I've used the same basic steps to make the armor with only a few additional techniques. So it may be easier to get started with some experience working with the foam in the helm project
I'll definitely give it a shot! I'd really like to do Lavitz's armor, from Legend of Dragoon; this stuff, if you're unfamiliar with it: http://media.photobucket.com/image/lavitz/waterworld119/LavitzModel.jpg<br><br> Does it look like a reasonable, simple set to start with? I don't want to start too complex and end up getting frustrated.
The scale looks reasonable and I think the armor itself doesn't look too intricate. It probably will be a good project to begin with, but if I were you I'd start with some smaller pieces of the set and work your way up. If you're like me, you'll waste a fair amount of foam before you get it to look right, but planning and designing patterns to cut out is probably the best thing you can do to reduce your consumption of foam and speed up the building process. Good luck! Hopefully I'll have enough time to finish my set of armor and can post another instructable in a reasonable amount of time. Until then, here are a couple of cool inspiring videos that might give you more ideas and techniques to work with:<br><br>http://www.youtube.com/watch?v=vb6CXGortrQ&amp;feature=results_main&amp;playnext=1&amp;list=PL412F405522C66539<br><br>http://www.youtube.com/watch?v=_S0zGnNVtxk
hardware stores sell thick cardboard tubes that are used for cement forms.
I haven't had luck finding them at hardware stores in my area, but that's good to know! Thanks for posting
this is really cool. great instructable.
You've shared some great techniques here. Thank you!

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Bio: I'm an aerospace design engineer with a degree in plastics engineering, and interested in doing cool stuff. I love building things and problem solving ... More »
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