I offered my local zoo to create a new Buzz Lightyear costume since their last one was basically a jumpsuit filled with polyfoam. I decided to make it out of EVA foam. I used pepakura files and rescaled several PDF breakdowns of his armor. Once I shaped the pieces with with a heat gun I glued them up with hot glued and sealed them with several layers of modge podge. I then painted with Krylon fusion and sealed them again with a high gloss polyacrylic. Here are some of my progress pics.