Arkham Knight super low budget foam build

oswaldthegreat

Jr Member
Hey everyone,
This is going to be by build thread/log on my Arkham Knight cosplay that I'm planning to make. I'm trying to make it as low budget as I possibly can, and it's going to be made out of EVA foam mats and some other stuff. Unfortunately, I'm in the middle of my exams at the moment, so I won't be able to work on it much until three weeks time, after which it is the end of my exams and the start of my 10 week :lol long summer. I'm mainly posting this thread here now to make myself remember to take pictures of the progress, and to get input on some things. I'm not all all going for anywhere near 100% accuracy, I'm aiming at maybe 50-60%(?), so that the main parts of the Arkham Knight's costume are captured, rather than all the little details (because his costume is possibly the most intricate and detailed costume I've ever seen).

Heres the list of things that I have and things that I need (predicted prices are shown in brackets):
Have
12 600x600mm EVA foam mats - £18
Assorted spray paints - £4 each (although can be found for £1 in a certain store near where I live)
Primer - already had, but £1
Black hiking/combat trousers - already had
Assorted 2mm foam craft sheets for details - £3
Need
Black undershirt - already have one, but it is covered in hot glue remnants from a previous build so I may need to get a new one for (£3)
Some sort of black/grey jacket - (£15) although may have one already, I just need to check.
Roll of 6mm camping mat foam - (£9)
Black (preferably) open face mask/balaclava thing - (£2)
...and probably some more things I haven't thought about yet.
Total cost so far (not including things I already had)- £25
Total predicted cost - £54 (and probably more)

I want to use straps and 'non-instrusive' methods to attach the armour to myself, rather than sticking it onto whatever I'm wearing underneath so that it I ever want to use the jacket for another cosplay it won't have glue marks all over it.

I started some work on the chest armour last night (although this will likely be the last I'll be able to work on it until after my exams). This is pretty much my first time working with EVA foam, and I'm using tutorials on YouTube such as Bill Doran, Evil Ted Smith and xieng prod to try and perfect my technique, so please bear with me if there are mistakes :D. As I said, the chest armour is made of EVA foam mats, and I used a rotary tool to bevel the edges, and then a heat gun to seal the foam to create a better surface for priming and painting. I'm not intending to use any other sealing agent such as Mod Podge or Plastidip, as although they give a superior surface, it is just an extra expense, and I have found that when testing sealing and painting foam that the surface that heating and priming gives is good enough for me. I am free handing the templates, and given the complexity of the Arkham Knight's armour, I don't know how well this will look in the end.
Anyway, here is the picture of the chest so far (please excuse the potato quality phone photo), there is still more to do on it, but I'm pretty pleased with how it's turned out so far:
IMG_20160606_134113.jpg

That's it for this post, as I said, if anyone does read this, don't expect any more pics or build updates until 28th June, although after that, I hope to update this thread at least once every three days (though I'll probably forget :facepalm). With any luck, this thread will force me to finish this cosplay!
 
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I just found Bandiet's Pepakura files and their foam unfolds, so I may try and use those templates instead of freehanding them as I previously planned to do as the templates will give a much more accurate armour design.
 
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