Picture of How To Make Foam Armor
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!
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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.

if im not mistaken this is from mass effect right?

CommandoNinja9 months ago

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

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.

it would be more advisable to use a repirator mask while ventilating the room.

DmitryS32 months ago

Commission projects?

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:
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
SkreemKing133 months ago

is there any way i could get any kind of template for the N7 defender armor from you??

ffrench4 months ago
What do you use for the gloves?
TobyM14 months ago

What thickness of foam would you recommend?

Call_meStark4 months ago

Is there a way I can contact you? Possible business?

Grafx4Life5 months ago
Did you just plasti-dip and paint or did you use wet sanding and multiple coats?
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!
AlecR5 months 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?
Jhiandn5 months 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?

Mystery98298 months ago
Is that halo armor?! If so awesome
TheBug7110 months ago

Where can you get reach Templates?

Hey, can you send me templates for the N7 defender?
austin421 year ago
Ok thanks sorry for answering so late forgot username
austin421 year ago
Ok thanks sorry for answering so late forgot username

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


The Irish Cowboy (author)  mironmember1 year ago

N7 defender

Aiden261 year ago
Does cutting the tabs off and using it for foam work with every pep file?
poofrabbit1 year ago
Congratulations on being a finalist in the Halloween costume contest! Can’t wait to see if you win good luck!
DHeigh1 year 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.
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)  DGMauriello1 year 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
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(
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