How to make cosplay knight armor?

Materials and Tools

• EVA foam (6mm thickness for main armor pieces, 2mm for details)
• Contact cement or hot glue
• Sharp utility knife or craft knife
• Heat gun or hairdryer
• Scissors
• Ruler and measuring tape
• Marker or silver gel pen
• Sandpaper (various grits)
• Primer (Plasti Dip or gesso)
• Acrylic paints (black, silver, and optional gold)
• Paint brushes
• Elastic straps and Velcro
• Rivets or eyelets (optional)
• Foam clay or Kwik Seal (for detailing)

Planning and Patterning

1. Design Your Armor: Start by sketching your desired armor design. Consider the main components: helmet, breastplate, backplate, pauldrons (shoulder armor), vambraces (forearm armor), gauntlets, tassets (upper leg armor), and greaves (lower leg armor).

2. Create Patterns: Use duct tape to wrap the body parts you'll be covering with armor. Cut the duct tape off carefully and flatten it to create pattern pieces. Alternatively, you can find pre-made patterns online or use the ones available at crazecosplay.com.

3. Transfer Patterns to Foam: Trace your patterns onto the EVA foam using a silver gel pen or marker. Remember to flip symmetrical pieces to create left and right versions.

Crafting the Armor Pieces

Breastplate and Backplate

1. Cut out the main pieces for the breastplate and backplate from 6mm EVA foam.

2. Use a heat gun to curve the foam pieces to fit your body shape. Work slowly and carefully to avoid overheating the foam.

3. Add details using 2mm foam strips. Cut decorative patterns or use a stamp to emboss designs.

4. Glue all pieces together using contact cement or hot glue.

5. Fill any gaps with Kwik Seal or foam clay for a seamless look.

Pauldrons (Shoulder Armor)

1. Cut out the main shoulder piece and smaller layered pieces from 6mm foam.

2. Heat and shape the foam to curve around your shoulder.

3. Layer and glue additional pieces for a more intricate design.

4. Create attachment points using elastic straps or buckles to secure the pauldrons to the breastplate.

Vambraces and Gauntlets

1. Measure your forearms and hands to create accurate patterns.

2. Cut the main pieces from 6mm foam and add details with 2mm foam.

3. Heat and shape the foam to fit comfortably around your arms and hands.

4. Add closures using Velcro or buckles for easy removal.

Tassets and Greaves

1. Create patterns for upper and lower leg armor.

2. Cut out the main pieces from 6mm foam.

3. Shape the foam using heat to contour around your legs.

4. Add detailing with 2mm foam strips or embossed patterns.

5. Attach the pieces using elastic straps or buckles for a secure fit.

Helmet

1. Create a pattern by wrapping your head in duct tape and carefully cutting it off.

2. Transfer the pattern to 6mm foam and cut out the main helmet pieces.

3. Heat and shape the foam to create the rounded helmet form.

4. Add details such as a visor, crest, or decorative elements using 2mm foam.

5. Create a chin strap or internal padding for a comfortable fit.

Detailing and Assembly

1. Edges: Bevel the edges of your armor pieces using a Dremel tool or sandpaper for a more refined look.

2. Texturing: Add texture to your armor by stippling with a soldering iron or using various tools to create patterns.

3. Sealing: Apply a coat of Plasti Dip or gesso to seal the foam and create a smooth surface for painting.

4. Assembly: Connect the various armor pieces using elastic straps, Velcro, or buckles. Ensure that the armor allows for comfortable movement.

Painting and Finishing

1. Base Coat: Apply a black base coat to all armor pieces using acrylic paint or spray paint.

2. Metallic Finish: Dry brush silver acrylic paint over the black base to create a metallic effect. Use light, sweeping motions for best results.

3. Weathering: Add depth and realism by applying a dark wash (watered-down black paint) to recesses and wiping away excess.

4. Highlights: Use a brighter silver or even gold paint to add highlights to edges and raised areas.

5. Sealing: Apply a clear sealant to protect your paint job and add shine if desired.

Tips for a Professional Look

1. Symmetry: Pay close attention to symmetry when creating paired pieces like pauldrons or gauntlets.

2. Comfort: Test the fit of each piece as you go and make adjustments for comfort and mobility.

3. Detailing: Small details can make a big difference. Consider adding rivets, embossed patterns, or foam clay sculpts to enhance your armor's appearance.

4. Weathering: Don't be afraid to add some wear and tear to your armor for a more realistic, battle-worn look.

5. Accessories: Complete your knight costume with accessories like a sword, shield, or banner bearing your chosen heraldry.

Maintenance and Care

1. Store the armor pieces flat or on a mannequin to maintain their shape.

2. Avoid exposing the armor to extreme heat or direct sunlight for extended periods.

3. Touch up paint as needed and re-seal periodically to protect the foam.

4. Handle the armor with care to prevent dents or tears in the foam.

Customization Ideas

1. Fantasy Knight: Use bold colors like deep blues, reds, or purples with gold accents for a more fantastical look.

2. Dark Knight: Create a sinister appearance with all-black armor and red or purple highlights.

3. Elemental Knight: Theme your armor around elements like fire (reds and oranges) or ice (blues and whites).

4. Royal Guard: Incorporate regal colors like purple and gold, with intricate designs and heraldic symbols.

5. Futuristic Knight: Blend medieval design with sci-fi elements for a unique, genre-bending costume.

Showcasing Your Armor

1. Photoshoots: Arrange a photoshoot in a suitable location, such as a forest, castle, or medieval-themed set.

2. Conventions: Wear your armor to cosplay conventions and participate in costume contests.

3. Online Communities: Share photos and build logs of your armor creation process on cosplay forums and social media platforms.

4. Local Events: Attend Renaissance fairs or medieval-themed events in your area.

5. Tutorials: Consider creating your own tutorial videos or blog posts to help others learn from your experience.

Conclusion