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. 
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?
<p>With foam, use Barge cement....like contact cement, but way less particulates. Contact becomes brittle when dry, Barge stays flexible. It is a US product that the shoe repair industry uses. I suggest the 1 quart size (smaller quantities cost too much, and unless you are making a legion, or working with it every day, the gallon is over kill. about $30 CDN for a quart. below is a link for a Movie prop house that makes crazy foam armor, and again they specify Barge. (BTW, I make props for the movies....intheshadows.ca ...)</p><p><a href="https://ca.video.search.yahoo.com/yhs/search;_ylt=A0LEVvAnJZpYQm4Aj74XFwx.?p=foam+armour&fr=yhs-arh-001&fr2=piv-web&hspart=arh&hsimp=yhs-001&type=xy_dc958702#id=1&vid=582e12d1d6b4529f41b5ff597d6586dd&action=view" rel="nofollow">https://ca.video.search.yahoo.com/yhs/search;_ylt=...</a></p>
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>
How long would EVA armor make, and one that doesn't have nearly as much detail ad yours?
<p>any were from 5 minutes to 1 month</p>
<p>I looked on the pepakura website and it's windows based. Is there anything for a mac?</p>
<p>windows! :D (sorry, biased ^.^') </p><p>blender has the ability to create similar paper sheets with a plugin, though i dont remember the name of it. there's also some other model unfolding software out there, but the name excapes me. do a google!</p>
What type of foam did you use and how much did it take? Roughly? Thanks this is a great tut for a great suit of armor!
Sorry u posted what type of foam so disregard that lol
About how many square feet of each EVA foam would i need to do this and could i also just take the outer parts of the helmet snd glue onto a old motorcycle helmet. Just email me back at baconlover540@gmail.com
<p>What type of foam would you recommend for making a master chief helmet ? </p>
<p>So I'm wanting to do a Halo cosplay but I'm not sure what pepakura is exactly and I'm having a hard time figuring out how i want to do the breast plate for a female character. Any tips or tricks??</p>
<p>Go to this page:<a href="http://www.405th.com/showthread.php?t=32947" rel="nofollow">http://www.405th.com/showthread.php?t=32947</a></p><p>There are the files for a female armor of Halo in pepakura, I hope it helps</p>
<p>You welcome :)</p>
<p>How Long did this take to make and how much did it cost </p>
<p>Would you happen to have a collection of the files (pdo./foam) you used? I'm looking all over and grabbing from here and there (405th and Pepakura Library), but honestly yours is a complete build I would love to have. Let me know, thanks! </p>
<p>This is a good link for armor designs </p><p>http://halocostuming.wikia.com/wiki/Pepakura_File_Index</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:
<p>What is that shirt you posted? I am looking for something exactly like that for airsoft.</p>
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>can you scale this for a ten year old?</p>
<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
<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>
<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>

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