Coating EVA in Urethane Rubber (In need of assistance.)

[The Prop Lord]

Hey guys!

So Halloween 2013 turned out fantastic. I made my brother a Dark Knight Rises Batman suit out of EVA foam and sealed it completely with Plasti-Dip Spray.

It's not 100% accurate, but it beats the store bought versions.

Basically I want to preserve it and make it more... durable. EVA foam can rip (and it has) and I dont want to continue to remake rib pieces. It's not expensive, just annoying.

I plan on having a "Show up at kid's b-day parties including choreographed fights and practical special effects" kind of mini business.

Batman will be doing crazy stuff, and while the suit is flexible, it is not exactly durable. So, I was thinking I could either coat the pieces in Urethane Rubber, or make molds of the suit and cast them from the rubber.

The problem is, I'm not exactly sure what rubber to buy, or even if it's a good idea. I looked around on Smooth-On but they don't exactly have a "Use this stuff to make costumes" option.

Can you please give me your opinions and/or suggestions.

Thanks!

 

[Armatus Cosplay]

It would be extremely difficult to coat your existing pieces in urethane rubber, cause it doesn't really stick to anything. Best bet is to make molds and cast new pieces. The standard rubber used for cowls is Vytaflex 40, which is made by smooth-on, and also works well for full suit castings. It can be strengthened with fiberglass mat placed inbetween layers while drying individual pieces, for added durability and tear resistance.


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[skittle76]

2nd that. Very well put and explained and I agree.