How to make fake armour for cosplay?

Planning and Preparation

1. Choose Your Character: Select a character whose armor you want to recreate. Gather reference images from multiple angles to understand the details and structure of the armor.

2. Select Materials: The most popular material for cosplay armor is EVA foam due to its versatility, affordability, and ease of use. Other options include:
   1. Worbla: A thermoplastic that becomes moldable when heated
   2. Craft foam: Thinner sheets ideal for detailing
   3. Cardboard: Inexpensive but less durable
   4. Metal: For advanced cosplayers seeking the most realistic look

3. Gather Tools: Essential tools include:
   1. Cutting tools (scissors, craft knife, hot knife)
   2. Heat gun
   3. Glue (contact cement, hot glue)
   4. Sandpaper
   5. Dremel or rotary tool
   6. Primer and paint
   7. Safety equipment (respirator, gloves, safety glasses)

4. Take Measurements: Accurately measure your body to ensure the armor fits properly. This includes length, width, and circumference of various body parts where the armor will be placed.

Creating Patterns

1. Use Reference Images: Carefully study your character's armor and break it down into individual pieces.

2. Create Paper Templates: Use paper or cardstock to create initial templates. This allows for easy adjustments before cutting into your foam.

3. Body Wrapping Technique: For a perfect fit, wrap the relevant body parts in plastic wrap and masking tape. Draw the armor shapes directly on the tape, then cut it off to create your pattern.

4. Digital Patterns: Some cosplayers use 3D modeling software to create precise patterns, which can then be printed and transferred to foam.

5. Test Fit: Make a mock-up using cheap materials like cardboard to test the fit and make necessary adjustments before cutting your foam.

Cutting and Shaping Foam

1. Trace Patterns: Carefully trace your patterns onto the foam using a marker or pen.

2. Cut Foam: Use sharp scissors or a craft knife to cut out your armor pieces. For thicker foam, a hot knife can provide cleaner edges.

3. Heat Shaping: Use a heat gun to carefully warm the foam, making it pliable. Shape it into curves and angles as needed, holding it in place until it cools and retains the shape.

4. Beveling Edges: Create realistic-looking armor by beveling the edges of your foam pieces. This can be done with a Dremel tool or by carefully sanding at an angle.

5. Adding Details: Use additional layers of thinner foam to create raised details, or carve designs directly into the foam using a soldering iron or Dremel tool.

Assembling the Armor

1. Test Fit: Before gluing, do a test fit of all pieces to ensure proper alignment and comfort.

2. Gluing: Use contact cement for a strong, flexible bond between foam pieces. Apply to both surfaces, let it become tacky, then press firmly together.

3. Reinforcing: For areas that will experience more stress, consider adding additional support with elastic straps or extra layers of foam.

4. Closures: Implement closures like Velcro, snaps, or buckles to make the armor easy to put on and take off.

Priming and Painting

1. Sealing: Apply several thin coats of Plasti Dip or a similar flexible sealant to create a smooth surface and prevent paint from cracking.

2. Priming: Once the sealant is dry, apply a primer suitable for your chosen paint type.

3. Base Coat: Apply a base coat in the primary color of your armor.

4. Detailing: Use acrylic paints to add details, shading, and weathering effects.

5. Weathering: Create a realistic worn look by dry-brushing darker colors in recesses and lighter colors on raised areas.

6. Sealing: Finish with a clear sealant to protect your paint job and add shine if desired.

Adding Final Touches

1. Weathering: Add battle damage or wear using techniques like dry brushing, sponging, or carefully applied heat distressing.

2. Accessories: Attach additional elements like gems, LEDs, or fabric components to complete the look.

3. Comfort: Add padding to the interior of the armor for comfort during long wear.

4. Straps and Fastenings: Ensure all straps and fastenings are secure and comfortable.

Tips from CrazeCosplay.com and Top-Ranked Tutorials

1. Start Small: Begin with simpler projects to build your skills before tackling complex armor designs.

2. Practice on Scrap: Always test techniques on scrap pieces of foam before applying them to your main project.

3. Invest in Quality Tools: Good tools will make your work easier and produce better results.

4. Join Communities: Engage with online cosplay communities for support, advice, and inspiration.

5. Document Your Process: Take photos and notes throughout your build to track your progress and learn from each project.

6. Be Patient: Quality armor takes time. Don't rush the process, especially when it comes to drying and curing times.

7. Prioritize Comfort: Remember that you'll need to wear this armor, possibly for long periods. Design with comfort in mind.

8. Stay Safe: Always work in a well-ventilated area and use appropriate safety gear, especially when working with chemicals or heat.

Troubleshooting Common Issues

1. Warping: If your foam warps after heating, try using lower heat and working in smaller sections.

2. Uneven Surfaces: Sand problem areas and apply additional layers of primer or Plasti Dip for a smoother finish.

3. Paint Cracking: Ensure your foam is properly sealed before painting, and use paints designed for flexibility.

4. Weak Joints: Reinforce high-stress areas with additional foam or fabric backing.

5. Uncomfortable Fit: Make adjustments to your patterns and add padding where needed for a more comfortable fit.

Conclusion