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