#cosplay armor how-to
Using expanding foam is a pretty straightforward process–you spray, carve, cover, and paint. You can’t get to that point if you don’t have the right tools, though. This is what you’ll need to make your next prop:
Cardboard
For making the base that the expanding foam will stick to.
Craft Knives
You’ll want a whole bunch of these–they get dull fast.
Masking Tape
Newspaper
Water
To help the foam rise.
Spray Bottle
Wallpaper Paste
You can use regular old Elmer’s Glue if you can’t find any, but this will work a lot better.
Paper Mache Clay
This may not be the paper mache you recognize. When mixed with water and glue it becomes a thick, clay-like material that is very durable once it hardens. It will give your prop its hard coating.
Sandpaper
For smoothing out the paper mache.
Since it isn’t a tool it isn’t listed above, I’ll write it here: remember to get several cans of expanding foam. You’ll carve away a half to two-thirds of the foam on your prop to get the right shape. You can also always add on foam and recarve if you make a mistake, but you’re out of luck if you don’t have any more left to use.
All of these materials are pretty cheap and commonplace–just pick them up from your local craft and hardware store and get working!
This guide was made under the wing of Costume Discounters (www.costumediscounters.com). Please go check out their site!! They sell wigs, shoes, shirts, essentials…all sorts of goodies.
You have to make sure you can use your prop without having it buckle and crack. Reinforcing cardboard is an essential step if you’re planning on using it for your costume! There are a couple different materials that will do the trick; here are some of them, listed from least hard to hardest:
Stiff fabric: Good for tight corners inside of props.
Fiberglass Tape: Not as stiff as craft foam, but easier to manipulate and layer.
Craft Foam: Good for the insides of worn props and those without steep curves.
Paper Mache Clay: Great for carving in intricate details, but not waterproof. It must be covered with a sealant after painting.
Gesso: Once sanded, it will leave your prop with a clean finish for painting. Must be covered with a sealant to make it waterproof.
Resin:The most common choice for cardboard and paper. Will make your prop smooth, strong, and waterproof, but it can be difficult to sand and has toxic fumes.
Bondo:Very, very strong, but isn’t waterproof. It must get a sealant top coat or be mixed with resin.
Just to prove how sturdy you can make these guys:
viaThorssoli
He’s standing on the helmet he just made. No supports, no hidden wires, no tricks–just good crafting. And it’s made out of paper(that link actually shows an excellent way to craft, reinforce, and paint if you want to check it out). Your prop will be able to stand up to most hard use as long as you reinforce it properly.
This guide was made under the wing of Costume Discounters (www.costumediscounters.com). Please go check out their site!! They sell wigs, shoes, shirts, essentials…all sorts of goodies.
