Anime Armor help

[Hotfix]

Hey guys!

So, for a friend of mine, I am going to build armor that should fit over her already existing outfit. The character in question is Saber, from Fate/Stay Night. Reference material isn't a problem since it's a well known series, but I do want some help with a plan of attack. How do I tackle this project?

I was thinking of making the chest and back plates and the gauntlets out of EVA foam (like this), reinforcing it from the backside with glue and cotton fabric, and giving it more thickness and sturdyness with friendly plastic (the pellet kind that melt in hot water). I would later add details (like the blue markings on her chest piece) with 3D paint.

Because I have no experience with these materials, I need to know:
-Is this the right foam to work with, or should I use something else? Should I get bigger sheets?
-Does it matter if it's colored foam, or should I really go for a neutral color like gray or white?
-Will Friendly Plastic bond with the EVA foam?
-Is there anything I should be careful with when heating up the foam to give it its shape?

If that works, I will paint it all with primer and proceed with painting it the way I like.
Last question, for this project, what is the one thing that would make it so much easier?

Thanks!

 

[EyeofSauron]

Hey guys!

So, for a friend of mine, I am going to build armor that should fit over her already existing outfit. The character in question is Saber, from Fate/Stay Night. Reference material isn't a problem since it's a well known series, but I do want some help with a plan of attack. How do I tackle this project?

I was thinking of making the chest and back plates and the gauntlets out of EVA foam (like this), reinforcing it from the backside with glue and cotton fabric, and giving it more thickness and sturdyness with friendly plastic (the pellet kind that melt in hot water). I would later add details (like the blue markings on her chest piece) with 3D paint.

Because I have no experience with these materials, I need to know:
-Is this the right foam to work with, or should I use something else? Should I get bigger sheets? no its way too thin. you should use at least 3 mm foam, 6 mm would be better.
-Does it matter if it's colored foam, or should I really go for a neutral color like gray or white?doesnt matter
-Will Friendly Plastic bond with the EVA foam?no idea, but i cant see it really bonding, and also it will deform the foam due to the heat while applying
-Is there anything I should be careful with when heating up the foam to give it its shape?always heat on the inside when using a heat gun. it can slighty bubble or crease, and therefor might not be a perfect surface afterwards, ifyoure not carefull. on the inside, it wont matter

If that works, I will paint it all with primer and proceed with painting it the way I like.
Last question, for this project, what is the one thing that would make it so much easier? coat it with pva glue. This way the foam will be sealed, and you wont have the problem of the paint being soaked up by the foam

Thanks!

there you go
also i dont know why the color tags dont work...

 

[Hotfix]

Thanks!

I see, so I should be getting sheets between 3 and 6mm thick. After reinforcing it, do you think it would be solid enough to pass as actual armor, or will it keep the feeling of foam?
And could you direct me to a webshop that ships to europe? It seems to be hard to find eva foam in the right thickness.

 

[PrimoOptimoso]

Hotfix - if you seal the foam and paint it, it won't be hard to the touch like fiberglass and resin, but the look should be pretty convincing. Sealing with Plasti-dip or even a glue works alright, and then do your best multicoat paint job to make it really smooth.

 

[EyeofSauron]

http://www.therpf.com/f24/list-supplies-suppliers-germany-europe-general-140144/

as for the armor looks: check all the foam iron man builds and judge for yourself.

it is not going to be rigid, but thats the point of foam. if you want something rigid, you would need something like a resin prop, or metal etc

 

[Hotfix]

Interesting, EoS, would you recommend plastazote above EVA or the other way around?

 

[EyeofSauron]

not a lot of difference, im guessing plastazote is easier for forming with heat, but barely. whatever material you like, just make sure that it has very small pores

 

[Hotfix]

Okay then! So, if I took 5mm LD45 (45kg/m3) Plastazote, that would be a good idea?
On eBay it's a little bit cheaper from 1,5m2 and up, so I guess I'll start with that!
As long as I can get both materials as smooth, i'll be fine

 

[Hotfix]

Bummer, the coscraft website is out of stock. Anyone have a better website?