Due to a few requests, I have decided to make a fairly detailed tutorial for my foam armor. This is my suit create last year from foam, Its my second suit of armor and I am currently working on my third. For the purpose of ease, I will be showing pictures from both suits to help show how a suit of your own might be made. Here is a list of needed materials for foam armor.

-A knife (carpenters or hot knife, or even a scroll-saw)
-Computer with printing capabilities
-Hot glue & Glue gun (I prefer one with low/high temperature setting so that you can quickly join parts and avoid burns)
-Paper, pens, ruler etc.
-Plasti-Dip, and spray paint
-A dremel.....very, very, VERY helpful.
-And of course.....the foam! I typically use EVA foam from three retailers which are all a little different in terms of composition. 
Home Depot->   Thinner foam that bends easily, has a diamond pattern on the reverse side.
Lowe's->              Thicker foam that doesn't bend as easily, very durable and has a hatched pattern on the reverse side
Harbor Freight->Thinner foam that bends easily, has a hatched pattern on the reverse side
Now that you have got everything, Lets Begin!

Step 1: File Collection and Printing

All over the internet are 3d models, some in Pepakura form that are craving to be made. If you're not sure what Pepakura is, it is simply a program that takes a 3d model and makes it into a net so that the 2d parts can be printed, and assembled in real life. The viewer program which allows you to also print can be found here: http://www.tamasoft.co.jp/pepakura-en/download/viewer.html  The Designer program, which lets you scale the parts to you can be found here: http://www.tamasoft.co.jp/pepakura-en/ If you ever need help printing/scaling/anything with Pepakura, simple search the web (There are tons of tutorials for that) or simply ask me and Id love to help. Once you have the model you want to be foam (Keep in mind that you can find these all over the net by searching say "halo armor Pepakura" If you can't find what you're looking for, it most likely hasn't been made into a 3d model yet. 
Ok, once you have the file, open it in the viewer and hit "Print". When all is done, you will have something like a pile of pages filled with polygons. Excellent, these will be your templates to trace on the foam. 
How long would EVA armor make, and one that doesn't have nearly as much detail ad yours?
<p>I'm trying to make my own custom halo armor in the same manner as my Halo: Reach spartan with the EOD helmet, the EVA shoulder plates, the default knee plates, wrist piece, default utility, default visor, and the default chest plate. I am just so confused. please HELP me out!!! my email is brokefang373@gmail.com and my number is 434-581-2160. THANK YOU!!!</p>
I'm trying to make red hood armor and I don't know how to work the computer like most I'm so confused please HELP my number is 254-833-3453
I'm trying to make red hood armor and I don't know how to work the computer like most I'm so confused please HELP my number is 254-833-3453
Please call me I'm in serious need of help my number is 254-833-3453
Anyway you can send me a link for the n7 armor? Having a rough time finding that particular template
I live in Arizona and some of my hot glue seams just melt right apart after a very short time in any amount of heat. Is there another type of glue I can use for the areas that need to be held together a little stronger?
I use goop all purpose glue. It takes longer to set but holds up to heat.
cyanoacrylic glues seem to work pretty well and can take the heat.
You can buy industrial hot glue it's big and yellow you need to buy a new gun for it but it's hi temp and strong as nails
<p>Thank you!</p>
<p>Be wary of to extreme of heats it can also melt the EVA. Use a combo of glue Tab some places with hot glue for a quick hold and use Barge contact cement, Gorilla glue or other type of glue that is not affected by Temperature.</p>
<p>Hello friend</p><p>You could decrime that you got the armudura n7 page defend Mass Effect, I do not find ... thanks</p>
For everyone looking for files, search around on 405th or the RPF. They should have what you are looking for. I unfortuntaly no longer have the files.
Where can I get the Mass Effect armor pepakura that you used? And how much did the whole Mass Effect armor cost you?
I had to custom make the templates from a model. The whole suit probably costed me about 350-500 to make.
<p>How do you add in a visor to it, and if it needs to be cut how would I do so? What brand of visor do you recommend? Sorry for all the questions just important things to know.</p>
<p>this would be epic for airsoft!!</p>
Hi. I want to make Liara's alternate armor. But I can't figure out how to make the pep file and at the right size. Also, I have no idea how to go about making the breast plate for a female. The rest seems doable. I just need a starting point. I've attached the photo of What I'm going for.
<p>if im not mistaken this is from mass effect right?<br></p>
<p>Doesn't EVA release toxic fumes when you heat it?</p>
Yeah, but as long as you try your best not to fully inhale tons of it, you should be okay. If you are heating it in your garage, just make sure you have a few doors open for ventilation.
<p>it would be more advisable to use a repirator mask while ventilating the room. </p>
<p>Commission projects? </p>
Hi :) Awesome make, best I've seen. What did you wear under the suit? <br>
Thanks! I searched around for a while, and finally found this:
Hey there, I was hoping for your help to scale some pep files for foam.
It's getting to the point where I should just use that as armour :) Great tutorial though.
Do you have a link for that? the boys down at the 405th have been looking for a good undersuit for the spartan 4 armor and this looks better than anything i've seen
<p>is there any way i could get any kind of template for the N7 defender armor from you??</p>
What do you use for the gloves?
<p>What thickness of foam would you recommend? </p>
<p>Is there a way I can contact you? Possible business?</p>
Did you just plasti-dip and paint or did you use wet sanding and multiple coats?
Latex based house paint (cheaper than plasti-dip) also works for sealing and priming the foam for your spray paint choice.
That's a great tip I've never seen anywhere. Thanks!
<p>How much did it cost you?</p>
dude it looks awesome i am trying to get into making a few things but it very hard to find ppl willing to talk to you like a newbie and not like youre stupid. I have a ton of questions and need some answered there are alot of things I want to make just need the right starter help lol. My son has been bothering me for spartan armor for a few years just trying to get it made somehow lol <br>
Shoot your questions! Send me a message if you'd like! :)
hey hey armor is badass. did you use an a4 printer for the templates?
I'm curious, what do you wear under the suit?
<p>Nice Tutorial, but can't find any .pdo or .obj on n7 defender anywhere and only see this site, can I also get a copy of the files you made?</p>
Is that halo armor?! If so awesome
<p>Where can you get reach Templates?</p>
Hey, can you send me templates for the N7 defender?
Ok thanks sorry for answering so late forgot username
Ok thanks sorry for answering so late forgot username
<p>hello can you send me the templates for this armor or the name so i can find it </p><p>thanks</p>
<p>N7 defender</p>
Does cutting the tabs off and using it for foam work with every pep file?

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