Instructables

How To Make Foam Armor

FeaturedContest Winner
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.

Materials:
-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!
 
Remove these adsRemove these ads by Signing Up
TheStuUurgE20 days ago
Hey, can you send me templates for the N7 defender?
austin4220 days ago
Ok thanks sorry for answering so late forgot username
austin4220 days ago
Ok thanks sorry for answering so late forgot username
mironmember28 days ago

hello can you send me the templates for this armor or the name so i can find it

thanks

FQ4V5X1HAQ3CFD6.LARGE.jpeg
The Irish Cowboy (author)  mironmember26 days ago

N7 defender

Aiden264 months ago
Does cutting the tabs off and using it for foam work with every pep file?
poofrabbit4 months ago
Congratulations on being a finalist in the Halloween costume contest! Can’t wait to see if you win good luck!
DHeigh5 months ago
You should show them a picture of the menu entry that shows the height, width & depth measurements, and who they should measure themselves to get the right size of template.
I didn't pay attention to that and made my first torso too small by 4 inches at the waist. I have to remake it now.
DGMauriello5 months ago
Where can I get the Mass Effect armor pepakura that you used? And how much did the whole Mass Effect armor cost you?
The Irish Cowboy (author)  DGMauriello5 months ago
I had to custom make the templates from a model. The whole suit probably costed me about 350-500 to make.
sq_10_e6 months ago
Latex based house paint (cheaper than plasti-dip) also works for sealing and priming the foam for your spray paint choice.
sq_10_e6 months ago
I have found that super glue used with a brush on applicator makes for really clean seams without the worry of hot glue globs plopping out.
leowrick696 months ago
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
The Irish Cowboy (author)  leowrick696 months ago
Shoot your questions! Send me a message if you'd like! :)
Alver3216 months ago
l
asalazar166 months ago
:O Y O U A R E A M A Z I N G !!!!! :D
Are you aware that EVA foam is slightly toxic and plasti-dip is VERY toxic? x(
Yes. Yes I am.
I've been searching and searching for the foam, does anyone know the best place??
EVA foam, Amazon and foam shops-just ask the person @ the front desk.
Craft foam (what i am using for my h4 master chief) @ most craft stores (Ben Franklin, Michaels, etc.)
teknozone8 months ago
These seriously look incredible. Keep it up.
Black Lotus8 months ago
This is awesome! How long did it take you to complete?
Ok sorry for the q's but I wanted to know how long this process usually takes (anyone who has done a project like this can anwser) oh, and also, I found a great place for pep. files! http://www.4shared.com/folder/CCB_6QwQ/405th_Pepakura_Database.html
Great job! One question though, where did you get the file for the Mark V armor, I can't find any. Could you please post the link in a comment?
Fairburn10 months ago
Your defender armor is sick! I was gonna give it a try but can't find the file. Keep up the good work and can't wait to see what else you make.
Benjamin11711 months ago
You sir did a great job with it, but I just have one question did you use printer paper or cardstock?
amiwa8511 months ago
Your Mass Effect Defender Armor look awesome. I've been looking for that Pepakura armor. where can i find pdo file fir that armor?
c3r3bra11 year ago
what did u wear under the legs part of the armor cause i saw what you wore under the chest part, but what about the legs?
you can also state everything you wore under the armor so legs chest hands head feet that would be nice thank you! :D
The Irish Cowboy (author)  c3r3bra11 year ago
Everything apart from the underarmour top and some track pants I got off of amazon, I wore the umpire pads over the shirt and the gloves I used were these: http://www.amazon.com/gp/product/B001QT6UBW/ref=oh_details_o03_s00_i00?ie=UTF8&psc=1:D I also got this neck seal later on http://www.amazon.com/gp/product/B002P51T76/ref=oh_details_o07_s00_i00?ie=UTF8&psc=1.
k2iran1 year ago
this Armor is something more than awesome!!!!!!!! :O
tvo61 year ago
where can I find the download for the wip defender armor?
The Irish Cowboy (author)  tvo61 year ago
I actually had to rip the file apart for making it, they arn't the prettiest ill admit that. PM me your email and ill send them! :D
jsabus1 year ago
Okay, so I am having major issues downloading stuff to Pepakura via 4shared. Is there any chance you could somehow send the files for some armor pieces on Pepakura to me?
The Irish Cowboy (author)  jsabus1 year ago
What armor pieces would you like? :D
jordanmar1 year ago
heres a video tut
http://www.youtube.com/watch?v=vb6CXGortrQ
The Irish Cowboy (author)  jordanmar1 year ago
Thanks......
Hi :) Awesome make, best I've seen. What did you wear under the suit?
Thanks! I searched around for a while, and finally found this:
undersuit.jpg
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
Pro

Get More Out of Instructables

Already have an Account?

close

PDF Downloads
As a Pro member, you will gain access to download any Instructable in the PDF format. You also have the ability to customize your PDF download.

Upgrade to Pro today!