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Picture of How To Make Foam Armor
chest14.jpg
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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NLegge7 days ago
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?
lwulfe NLegge5 hours ago
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

this would be epic for airsoft!!

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.
rtfa0n.png

if im not mistaken this is from mass effect right?

CommandoNinja10 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.

DmitryS33 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:
undersuit.jpg
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
SkreemKing134 months ago

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

ffrench5 months ago
What do you use for the gloves?
TobyM15 months ago

What thickness of foam would you recommend?

Call_meStark5 months ago

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

Grafx4Life6 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!
AlecR6 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?
Jhiandn6 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?

Mystery98299 months ago
Is that halo armor?! If so awesome
TheBug7111 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

thanks

FQ4V5X1HAQ3CFD6.LARGE.jpeg
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.
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