Instructables
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!
 
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Did you just plasti-dip and paint or did you use wet sanding and multiple coats?
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
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
sq_10_e1 year ago
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!
AlecR7 days ago

How much did it cost you?

leowrick691 year 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)  leowrick691 year ago
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?
Jhiandn29 days ago

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?

Mystery98293 months ago
Is that halo armor?! If so awesome
CommandoNinja4 months ago

Doesn't EVA release toxic fumes when you heat it?

TheBug715 months ago

Where can you get reach Templates?

TheStuUurgE7 months ago
Hey, can you send me templates for the N7 defender?
austin427 months ago
Ok thanks sorry for answering so late forgot username
austin427 months ago
Ok thanks sorry for answering so late forgot username
mironmember7 months 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)  mironmember7 months ago

N7 defender

Aiden2610 months ago
Does cutting the tabs off and using it for foam work with every pep file?
poofrabbit11 months ago
Congratulations on being a finalist in the Halloween costume contest! Can’t wait to see if you win good luck!
DHeigh11 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.
DGMauriello11 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)  DGMauriello11 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_e1 year 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.
Alver3211 year ago
l
asalazar161 year 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.)
teknozone1 year ago
These seriously look incredible. Keep it up.
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?
Fairburn1 year 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.
You sir did a great job with it, but I just have one question did you use printer paper or cardstock?
amiwa851 year 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?
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