Instructables

Faux-Metal Jewelry (or Armor) Out of Foam

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This is something that might be considered halfway between Dara and my specialties. I make armor. Dara makes crafts. 

This is a cheap way to use crafts to make faux-metal pieces. I have used these methods to make armor that looks like real, decorated armor pieces, but is amazingly cheap and can be made at home with bare instruments for halloween, theater, or cosplay.

Things you'll need:
Design
Craft foam
Knife/scissors, iron, hole-punch, paint brush
Paint, glitter, beads, other decorative items.

Jewelry is the main focus of this Instructable, but you can use the knowledge for crafting lightweight armor as well. 
 
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Step 1: Create the Design

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Some thick paper would work best for this step. You can also find designs for this online or at craft stores.

Heck, if you're pretty good at tracing or free-hand drawing, you can create your own. Celtic knot designs work well for most jewelry or medallions. Dara likes to make 2 patterns, a blank cutting pattern for the bigger pieces and a clear marking or drawing pattern for jewelry she has to do multiple times. This works especially well for multiples.

Step 2: Trace/Cut Out Pieces

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After you have the design, choosing how to use your foam is the next step. There are a few options to manage this step:

Iron on a metallic fabric to the craft foam.
Find metallic-shaded craft foam.
Choose generic craft foam, then spray paint it later. (This is the cheapest)

After you've chosen your method, cut out the design you've come up with. If it's one piece, you can use a soldering iron with a flat face to press in the foam to make it look overlapped.
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