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  1. XRobots's Avatar
    Member Since
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    Southampton, UK
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    Apr 29, 2012, 8:19 AM - How to plastic coat foam costume pieces #1

    I've been doing some testing with plastic coating plastazote foam, although I've only tried it a couple of times, I'm pretty sure it could give some amazing results with practice. Essentially this gives you the speed and ease of foam building with the finish of plastic or fiberglass pieces.

    Here is my foam test piece:



    It also works for expanded polystyrene and other materials, so I think my next project will be a Terminator Endoskeleton made out of foam, carved polystyrene, cardboard tubes etc, all plastic coated and painted up like metal.

    Here's an article with words: XRobots.co.uk/coating

    And a YouTube video showing the step by step process: XRobots - How To plastic coat foam & expanded polystyrene prop and costume pieces - YouTube

    Last edited by XRobots; Apr 29, 2012 at 8:25 AM.
  2. endo500's Avatar
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    Jun 2011
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    Apr 29, 2012, 9:43 AM - Re: How to plastic coat foam costume pieces #2

    wow great idea. I'm building a foam costume and was worried about how i would not have that look of painted foam. Thanks I again I can't wait to try this method out. Plus the video was very good and detailed.
  3. Member Since
    Apr 2010
    From
    Perth Australia
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    Apr 29, 2012, 10:05 AM - Re: How to plastic coat foam costume pieces #3

    Nice!.
    Please excuse my ignorance, but what is the advantage in using the smooth on rotocasting stuff over say just fibreglass? Could you use the same process you described using fibreglass resin? (nice tip on using PVA as a primer )
  4. XRobots's Avatar
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    Southampton, UK
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    Apr 29, 2012, 10:07 AM - Re: How to plastic coat foam costume pieces #4

    Woodlake said: View Post
    Nice!.
    Please excuse my ignorance, but what is the advantage in using the smooth on rotocasting stuff over say just fibreglass? Could you use the same process you described using fibreglass resin? (nice tip on using PVA as a primer )
    Yes possibly, but without reinforcement polyester resin would be quite brittle, the Polyurethane is much better in thin sections.
  5. jackieisrockin's Avatar
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    Oct 2011
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    Apr 29, 2012, 3:37 PM - Re: How to plastic coat foam costume pieces #5

    Would smooth on 300 or 320 work for this?
  6. EyeofSauron's Avatar
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    Austria
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    Apr 29, 2012, 4:02 PM - Re: How to plastic coat foam costume pieces #6

    brilliant, bloody brilliant. you allways surprise me

    did i catch that right that you used 10 mm foam for the im suit? isnt that a little hard to work with?
  7. Member Since
    Apr 2012
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    Apr 29, 2012, 6:04 PM - Re: How to plastic coat foam costume pieces #7

    loved the tut man it was excellent. iv always had problems with seems in my foam armour and my outer layer cracking this seems like it could be the answer to all my problems ordered some resin of ebay gonna give this a go on one of my shoulder bells and see how they come up thanks very much buddy
  8. Member Since
    Feb 2012
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    Apr 29, 2012, 6:11 PM - Re: How to plastic coat foam costume pieces #8

    Is "plastazote" basically the same as the EVA closed cell foam that's used in the floor mats most people use?

  9. Member Since
    Dec 2010
    From
    Eastbourne, East Sussex, UK
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    221
    Apr 29, 2012, 6:27 PM - Re: How to plastic coat foam costume pieces #9

    vargatom said: View Post
    Is "plastazote" basically the same as the EVA closed cell foam that's used in the floor mats most people use?

    Yes - this is used by many foam builders
  10. Member Since
    Jan 2010
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    216
    Apr 29, 2012, 6:29 PM - Re: How to plastic coat foam costume pieces #10

    Most impressive!

    How dose this hold up on high stress parts, is there much cracking or crazing?
  11. drakeprimeone's Avatar
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    Jan 2012
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    Apr 29, 2012, 6:48 PM - Re: How to plastic coat foam costume pieces #11

    Very very cool, will need to try this out
  12. Member Since
    Feb 2012
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    Apr 29, 2012, 7:14 PM - Re: How to plastic coat foam costume pieces #12

    widescreen said: View Post
    Yes - this is used by many foam builders
    Yeah, I'm using it too, but the rolled up sheet in the video looked quite different and I was wondering if it's the same material...
  13. Member Since
    Apr 2010
    From
    Perth Australia
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    Apr 29, 2012, 8:00 PM - Re: How to plastic coat foam costume pieces #13

    XRobots said: View Post
    Yes possibly, but without reinforcement polyester resin would be quite brittle, the Polyurethane is much better in thin sections.
    Ah - makes sense. Thank you
  14. Member Since
    Apr 2010
    From
    Oshawa, Ontario, Canada
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    Apr 29, 2012, 9:48 PM - Re: How to plastic coat foam costume pieces #14

    Very nice tutorial. Your website is very informative but I am also wondering how strong it is and will there be much cracking if this is used on an Ironman suit?
  15. Universal Greeblie RPF Premium Member Jedifyfe's Avatar
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    Apr 29, 2012, 10:06 PM - Re: How to plastic coat foam costume pieces #15

    Brilliant! And great tutorial!
  16. RPF Premium Member Sonjou's Avatar
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    Apr 29, 2012, 10:34 PM - Re: How to plastic coat foam costume pieces #16

    Nice ! thread subscribed.
  17. XRobots's Avatar
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    Southampton, UK
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    Apr 30, 2012, 2:55 AM - Re: How to plastic coat foam costume pieces #17

    Thanks guys, to answer a few questions:

    -Yes I'm using 10mm foam, but you could probably use 5mm thinnest I'd say. I had some lower density 5mm foam and it was quite 'floppy', so you might want to put cardboard formers in the piece before coating it.

    -I've only used Smooth cast 65D which is a rotocast resin, which means it 'self levels' and gives a nice smooth surface - normally on the inside of the piece. You could try other Urethane resins, but you probably want lots of thin coats to avoid lumps.

    -In terms of strength it feels pretty good, but what you see is all I've made using this process so far. It might be worth coating the inside as well as the outside of the piece for extra strength, and at that point you could always reinforce the inside with more resin as thick as you like.

    -The foam I'm using is Plastazote from: Thames Valley Supplies - Rubber & Foam Converters - Rubber Snow Plough Blades
  18. RPF Premium Member Canobi's Avatar
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    Apr 30, 2012, 4:10 AM - Re: How to plastic coat foam costume pieces #18

    What an ingenious idea, thanks so much for sharing

    I've just got templates for the M7 armour and helmet. I'm planning on making three, one for me, and one each for my boys
    Oh yeh, and thanks for the link to a foam sheet supplier in the uk, it's really hard trying to find alternatives to materials that are used in the US.
  19. Member Since
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    Apr 30, 2012, 4:27 AM - Re: How to plastic coat foam costume pieces #19

    Canobi said: View Post
    What an ingenious idea, thanks so much for sharing

    I've just got templates for the M7 armour and helmet. I'm planning on making three, one for me, and one each for my boys
    Oh yeh, and thanks for the link to a foam sheet supplier in the uk, it's really hard trying to find alternatives to materials that are used in the US.
    hey man im in the uk to i was having the same problem but i found out that those camping and yoga matts are made of the same stuff and they come in good size rolls i buy them form argos and a place called B and Ms there very cheep and work really well. make sure to inspect them before bringing them home cus you get some denser than others. check out the facebook page it shows some stuff iv made with the matts Iron man armour uk | Facebook
  20. Member Since
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    Apr 30, 2012, 7:18 AM - Re: How to plastic coat foam costume pieces #20

    firebapx said: View Post
    hey man im in the uk to i was having the same problem but i found out that those camping and yoga matts are made of the same stuff and they come in good size rolls i buy them form argos and a place called B and Ms there very cheep and work really well. make sure to inspect them before bringing them home cus you get some denser than others. check out the facebook page it shows some stuff iv made with the matts Iron man armour uk | Facebook
    i used camping mats for my ironman build and im in the uk i started off buying the garage floor mats but found them at 12 mm that they were just to think for what i wanted to do with them, so then i brought 3 mm camping mats which was ok.i made the shoulder armour with it painted them up and since finishing the suit have relised they are just to thin as they have start to rip in places.the rest of the suit i brought 6 mm camping mats which i found at a good price in wilkinsons and find these perfect strong enough to take some stick but flexible enough to bend into any shape you want
  21. RPF Premium Member Canobi's Avatar
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    Apr 30, 2012, 9:53 AM - Re: How to plastic coat foam costume pieces #21

    Thanks for the heads up on foam matting guys I'll pop in to Wilco's and get some
  22. RPF Premium Member Darth Lars's Avatar
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    Stockholm, Sweden
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    Apr 30, 2012, 11:07 AM - Re: How to plastic coat foam costume pieces #22

    Great info! Thanks for making the vid. This will become useful.
    Too bad that I can't get rotocasting resin locally, I could need the extra durability.
  23. Finhead is offline Finhead
    Apr 30, 2012, 11:25 AM - Re: How to plastic coat foam costume pieces #23

    Get tut and idea.
    Few tips about 65D though. It likes to delaminate if you leave it between coats too long. I woul do all or most of your coats in a row then scuff and a final coat. You can also use a heatgun or hairdrier once your done painting the resin on to level it a little better and get rid of any little bubbles that have formed from the brush action.
    Just wanted to add those to help you out a bit since it looks like a nice easy quick process that should help a ton of people. Oh and 65D is perfect since it is so very flexible compared to other casting resins.
    Again great job and thanks for sharing.
  24. CSMacLaren's Avatar
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    Apr 30, 2012, 2:44 PM - Re: How to plastic coat foam costume pieces #24

    Wow, brilliant! Thanks for sharing!
  25. DarthVeach's Avatar
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    Aug 2007
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    Lewis Center, Ohio
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    Apr 30, 2012, 7:55 PM - Re: How to plastic coat foam costume pieces #25

    This is the kind of thing I was hoping someone would test out!! I am so happy to see it working too! Way to go James! I was going to get Epoxamite and try it, but I like that Finhead mentioned that 65D has more flex to it. Probably won't crack as easy as Epoxamite would!

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