Here's how I joined mine with some regular screws. Hope this will help you
Hey mate, sorry for the long response, I've been busy with the olympics as well and took some time to take a little break but I'm back now
I used a regular soldering iron too, with a pointy end :
I have to trace the lines quick cause my foam is pretty soft and burns very fast, otherwise I would end up with a big hole in it :lol
I guess you couls try goind slower, depends of the density of the foam you're working with. Just try differents method, you'll find the good pace
Looks really neat so far for the paper fit test, a bit big though but you'll find the right scale
I did a complete fit test the other day and boy I'm disapointed..
The legs came out few inches too short :facepalm
I'm a bit mad cause they actually fit me perfectly (around my thigh) with a nice tight feel, just like the arms. I used the same scale for arms/legs but i guess I should of have use a bit larger one for my legs..
Don't feel like re doing them AT ALL so I'm already worlinkg on lowering the abs/cod to gain the few laking inches
I'm currently gluing the upper thigh pads as I'm writting this post so the big hollow between the legs and cod is goind to be covered, don't worry guys :lol
Scaling is really the most important part of the built so take your time and don't rush it. It makes your suit looking from just nice to awesome
Any way, looks fine from the back though..
ps : Don't mind the silk pyjama, I was too bored to change my under outfit :lol