Creating an EVA Foam Armor Piece - Part 1
Locate several reference photos for your desired character.
1
Isolate and enlarge one armor piece in an imaging program, his belt buckle in this case.
2
Print to desired size. Fold for symmetry. Cut out. Trace onto cardstock.
3
Repeat template process for details. Check for sizing.
4
Select your desired foam thickness. These samples range from 2-10mm. I went with 4mm.
5
Trace templates onto EVA foam.
6
Cut out with a very sharp Xacto knife then smooth edges with a Dremel.
7
Heat seal all surfaces with a heat gun. You can also bend and form the pieces while they’re warm.
8
Apply contact cement to both sides of surfaces to be joined. Allow to dry.
9
Press dried cement sides together. This creates a permanent bond.
10
Embellish with EVA foam dowels, foam clay, or craft foam details.
11
I’ll finish it in part 2. Stay tuned.
12
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