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Foam and Worbla armour MEGA TUTORIAL by AmenoKitarou Foam and Worbla armour MEGA TUTORIAL by AmenoKitarou
Brace yourselves! The MEGA tutorial is coming. 
Part 1 Foam Shaping, Part 2 Foam Detailing, Part 3 Worbla

You will need to view full size to read this monstrosity
I hope this will help someone, somehow, someday~! 
Please leave feeback and share! Enjoy. 

P.S. PLEASE READ FAQs before asking questions in comments 

- What kind of foam? Where do I buy?
EVA foam. 5mm thick. I buy it in the form of a gym mat from local malls. 

- What kind of glue?
I use contact adhesive (you can buy this at any hardware store). But hot glue also works~

- Where can I buy worbla?
If you are in Sydney, there is a place that stocks it locally called The Sarlacc Pit in Parramatta. If you are elsewhere... I have no idea. Google "Buy Worbla Online" maybe?

- I can't afford worbla. What can I do?
Follow the tutorial until the end of Part 2. Then seal and paint it as a foam armour. Part 3 is completely optional. 

- I tried this and it didn't work so well. 
Practice. Fail. Repeat. Learn.

- Video tutorial?
There is nothing exciting about listening to my voice while I do tedious things. So I assure you this is the best medium. 

- Commissions?
Yes. PM for details and quote.

- I thought you disliked worbla? 
I do. But since there are many people out there who love worbla, and I am working with it now, why not share some knowledge?
Add a Comment:
fractured100 Featured By Owner Mar 16, 2018  Hobbyist General Artist
Nice! Covers what you need to know and easy to follow!
DIMProps Featured By Owner Feb 22, 2018  Hobbyist Artisan Crafter
An amazing tutorial, thank you.
elconort Featured By Owner Oct 21, 2017
Thank you thank you thank you!  Very easy to understand and follow!  Very sincerely, a mom making her daughter's Water Dragon Warrior Princess armor with no EVA\Cosplay experience!
ThoxCosplay Featured By Owner Edited Oct 19, 2017  Hobbyist Artisan Crafter
nice tutorial!
Wayuki Featured By Owner Feb 13, 2017  Professional Digital Artist
Thanks for sharing your process!
TatsukiOtaku Featured By Owner Nov 26, 2016  Student General Artist
Do you have an exact store you buy EVA from? I bought some online, I believe it was 1cm, but its so thick and hard to maneuver/bend into shape.
callianis Featured By Owner Aug 29, 2016
Watch the sun rise :D
Green-Raincoat Featured By Owner Jul 19, 2016  Hobbyist Digital Artist
Actually, very helpful. Thank you! :)
KarraKon Featured By Owner Jul 10, 2016  Hobbyist Digital Artist
Thank you so much for the tutorial.. gonna try it at home later!
A question.. how do you seal/coat the foam before coloring them? (is this the right term?)
the foam I had in my country have these little holes and when I try to primer it with pilox airbrush spray it wouldn't get even and I can see more little holes DX
RollEXE Featured By Owner Sep 6, 2016  Hobbyist Digital Artist
I think you'll need a high density foam, it might be called EVA foam, or floor matting (the jigsaw piece ones), or like mattress foam (for when you go camping and put under your sleeping bag). This foam has tiny weeny holes and you can seal it with PVA/school/white glue, gesso, etc. I like to seal it with hairspray. :> I hope this helps?
lenatsukimori Featured By Owner Jun 28, 2016
I hope you do someday about how to make armor and swords with just foam or rubber sheet.
ThoxCosplay Featured By Owner Edited Oct 19, 2017  Hobbyist Artisan Crafter
that works just the same way, only without the worbla ;)
when you're done with all the foam shaping, seal/prime it with e.g. plastidip (that's what i did, i've seen other options here in the comments and all over the net if you search for it). afterwards you can paint on it with acrylic paint.

edit: and now i saw that he gave just the same answer in the description... :D
exifri Featured By Owner Apr 2, 2016  Hobbyist Artisan Crafter
Jesus christ it's so good I almost cry XDDDDDDDDDDDD 
If you don't mind, I will share it on my facebook page - for people who don't understand complicated tutorials! Like me! Ha! :D :D :D 
AmenoKitarou Featured By Owner Apr 2, 2016  Hobbyist General Artist
Thank you so much.
If you don't mind, please share this via my facebook album :)
My page name is: Amenokitarou (A.K.WIRRU)
exifri Featured By Owner Apr 3, 2016  Hobbyist Artisan Crafter
Sure!! :) I'll share you with my page, so maybe you'll earn some likes from my people! Haha ! :D :D 
AmenoKitarou Featured By Owner Apr 2, 2016  Hobbyist General Artist
Thank you so much.
If you don't mind, please share this via my facebook album :)
My page name is: Amenokitarou (A.K.WIRRU)
kawaii-chocolate Featured By Owner Mar 27, 2016  Hobbyist Digital Artist
I found out the hard way if you leave worbla sitting in the heat it will fall apart and make you cry more. >_>; 
Hinonoona Featured By Owner Jan 25, 2016
Why use the worbla over the foam? Is it just preference? Can't you get a similar finish without the worbla?
VelvetRoseCreations Featured By Owner Feb 5, 2016
Personally, I think it is mostly preference. But adding Worbla (or wonderflex) makes it very stiff. So you can bump, drop, step on it and it wont get ruined. If it's just foam, it can bend and get creases or even crack your paint layer if not done well.
AmenoKitarou Featured By Owner Apr 2, 2016  Hobbyist General Artist
I mainly do it only to projects that I know I'll travel with a lot.

I rarely use worbla but when I do it's always over a foam base.
LucaLouise Featured By Owner Dec 23, 2015  Hobbyist General Artist
What do you use to glue the pieces of foam together? And what is the thickness of the foam? :)
LorenzoAndre Featured By Owner Nov 24, 2015
What is worbla?
EwiZew Featured By Owner Nov 19, 2015
What will happen if I just make that part with eva foam? If I have a "ready" armor with all lines and all, but no worbla on eva foam. Can it be good without worbla, too?
iAnubis Featured By Owner Nov 22, 2015  Hobbyist General Artist
He mentions above that if you can't find/afford worbla, you can just paint it to look like armor and you're good to go -- the worbla part is optional. :) Hope that helps, and good luck with your armor. 
steave1425 Featured By Owner Oct 23, 2015  Hobbyist General Artist
That's awesome. Thanks for making. :happybounce:
karmaqueen588 Featured By Owner Sep 29, 2015  Hobbyist Digital Artist
You just solved so many problems for me. i love you so much right now~
LucaLouise Featured By Owner Sep 28, 2015  Hobbyist General Artist
Do you think this will work for a breastplate as well? I recently made this one:…
When I finally have enough money to afford Worbla, could I just cover the breastplate in the stuff like with your method? (I don't want to start over >.<)
StrawberrySunflowers Featured By Owner Aug 25, 2015  Student General Artist
You are an angel!!! Thank you! <3 
snoopygirl11 Featured By Owner Aug 17, 2015
Awesome tutorial ^^
NekoRushi Featured By Owner Aug 12, 2015   Artisan Crafter
Holy crap, this is GOOD. I need practice on foam shaping, rly bad
LoelJGrey Featured By Owner Jul 23, 2015  Professional Traditional Artist
The BEST HOW TO WORBLA ever found!!! AMAZING! Thanks for sharing it with us!
puenn Featured By Owner Jun 30, 2015
great job!
Wait0wat Featured By Owner Jun 27, 2015
This tutorial will prove most useful when creating the Golden Fleece from "God of War III"
greywolfeone Featured By Owner Jun 23, 2015
does the contact adhesive give you more time to get the edges together better and have less gaping, thus giving you a smoother finish that will be filled in with the PVA glue finish before paint.  I am just starting to play with the foam and I tried hot glue on a large edge and had trouble getting a nice seam.
Ginsu85 Featured By Owner Jun 12, 2015
This is gonna be very helpful for what I have planned... thank you for the tutorial...
NatanThe6th Featured By Owner May 2, 2015
Hahaha I love how you explained the steps :p :p great work.
Arsanni Featured By Owner May 1, 2015  Hobbyist Artist
what is this brown....paper?
NatanThe6th Featured By Owner May 2, 2015
It's called Worbla, it's a thermoplast.
rwolf1970 Featured By Owner Apr 24, 2015  Professional Artisan Crafter
Thanks man, looking for some tips on my first foam project, nice work :)
kupieckorzenny Featured By Owner Apr 17, 2015  Student Digital Artist
I've always been a bit intimidated by eva foam, but this seems to be simpler than I thought! (though still now easy, of course). Cosplay I'm working on requires pauldrons only (not full armor) so it's a good way to start :) Thanks a lot!
SupaaNeko Featured By Owner Apr 13, 2015  Hobbyist Photographer
Simple, yet really got the point across. Freaking love it.
R62 Featured By Owner Apr 8, 2015  Professional Filmographer
Dumb question, but I assume this can work for Halo armour templates as well? Just curious since it has a LOT of details too :P
DesignerTJP Featured By Owner Mar 12, 2015  Professional General Artist
Hi! Great FX Shop Humor you have! I can feel your pain that you've been up at 3:00am several times on your cool projects. Thanks for your Tutorial!
OceanPirate Featured By Owner Edited Feb 23, 2015  Hobbyist Digital Artist
For foam, should we use EVA foam or would craftfoam work aswell? I use a 6mm craftfoam, even for details,but when I try to bend it, it won't allow me to,so now I'm stuck with a lot of seams in my details. I readed about using hot glue....How does that work? Putting hot glue on the seam,and pushing it together?
Kiteera Featured By Owner Feb 16, 2015  Hobbyist General Artist
Loved this! I'm in the beginning stages of a Star Wars: The Old Republic cosplay. I found plenty of helpful tips in here, thanks a million!
KiraVanndrea Featured By Owner Jan 29, 2015  Hobbyist General Artist
Thanks for the great tutorial!
Markonator Featured By Owner Jan 20, 2015  Hobbyist General Artist
Funny+helpful=perfect! :D
SeeKaz Featured By Owner Dec 14, 2014
Aweee-ssoomee ,amazing :D :D
Wild-Fire-1187 Featured By Owner Dec 12, 2014   General Artist
If I may place a recommendation: Harbor Freight Tools stores sell EVA foam sheets, 12x12 feet for $8. It's good foam, used for workshop floors, and you get a good lot of it for a good price.
CrystalArwen Featured By Owner Dec 2, 2014  Hobbyist Artist
Hello, this tutorial is awesome! Can I translate it to russian an post into russian cosplay community on ? I will add a link on your Deviantart
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Submitted on
July 13, 2014
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