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I finished my Lightning Returns boots today!!
I took some progress photos throughout the process & thought it might be help others making armor out of craft foam. It's really lightweight & affordable! (cost me under $10
How I did it:
1:Cut a pattern out of paper.
2:Trace pattern onto craft foam & cut it out.
3:Use stove (or heat gun) to warm up foam so it's moldable for shaping.
4:Trace pattern on poster board or cardstock & glue it under the shaped foam to stabilize it.
Tip: if you need raised edges just hot glue on strips of foam.
5: Glue separate solid pieces together if necessary
6: Coat foam in clear craft glue & let dry.
7: Spray paint base coat (darker color)
8: Paint/detail desired color
9: Attach elastic, velcro, straps, ect.. in desired areas to make it wearable
10: Put it on & look like a badass! ;D
I took some progress photos throughout the process & thought it might be help others making armor out of craft foam. It's really lightweight & affordable! (cost me under $10
How I did it:
1:Cut a pattern out of paper.
2:Trace pattern onto craft foam & cut it out.
3:Use stove (or heat gun) to warm up foam so it's moldable for shaping.
4:Trace pattern on poster board or cardstock & glue it under the shaped foam to stabilize it.
Tip: if you need raised edges just hot glue on strips of foam.
5: Glue separate solid pieces together if necessary
6: Coat foam in clear craft glue & let dry.
7: Spray paint base coat (darker color)
8: Paint/detail desired color
9: Attach elastic, velcro, straps, ect.. in desired areas to make it wearable
10: Put it on & look like a badass! ;D
Image details
Image size
2686x2409px 1.23 MB
Make
Canon
Model
Canon PowerShot SX40 HS
Shutter Speed
1/13 second
Aperture
F/2.7
Focal Length
4 mm
ISO Speed
1600
Date Taken
Dec 7, 2013, 3:35:05 PM
Sensor Size
4mm
Published:
© 2014 - 2021 AlysonTabbitha
Comments28
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I'm later as hell, and i'm not the best at armor...
but i can tell you that craft foam is generally 2mm thick, if you're getting the sheets.
Sometimes craft foam is labelled "eva foam sheets" in some shops, but when cosplayers are talking about EVA foam, we're normally on about the floor mat kind.
Hope this helps in the future!
but i can tell you that craft foam is generally 2mm thick, if you're getting the sheets.
Sometimes craft foam is labelled "eva foam sheets" in some shops, but when cosplayers are talking about EVA foam, we're normally on about the floor mat kind.
Hope this helps in the future!

I'm late in hoping out here, but hey! the more you know!
I've used tacky glue in the past on craft foam, many to prime AND seal, but the downside is that tacky glue normally drys shiny.
But you may or may not have heard of Mod Podge, right? Mod Podge can be used the same way that tacky glue can, but you can get different varieties of it! So you can get the Gloss one or the Matte one!
Hope this helps out in the future!
I've used tacky glue in the past on craft foam, many to prime AND seal, but the downside is that tacky glue normally drys shiny.
But you may or may not have heard of Mod Podge, right? Mod Podge can be used the same way that tacky glue can, but you can get different varieties of it! So you can get the Gloss one or the Matte one!
Hope this helps out in the future!
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