Greetings All! My name is Darth Yega (Darth Yay-ga). I am new to the rpf forums, and this is my first post on the forums, (and certainly will not be my last. ) I have a question concerning foam armor. My question is: How can I construct the pectoral armor you would see on a Spartans plate body (like this: http://holywars2010.files.wordpress.com/2010/10/hoplite4thcentury.jpg)? I am constructing a custom Star Wars costume based off of the old republic era, with ½ inch thick foam mats (I have about 12 mats, one of which was used today, making it 11) I have made the main torso armor; it fits the general shape of my torso very well. I should post pictures of it soon. It is flat in the front (it is only the front half of the torso, starting at my waste line proceeding to the top of my shoulders. It looks like a black tank-top, lol), besides the curve it has to fit my torso. So in essence, it is flat because I do not have big enough pecs to make any more curves, lol. I was thinking, maybe I should cut out of one of the foam mats to the shape of the pecs, and shoot them with the heat gun to round them out like pecs, and then attach them to the main torso armor. Once on the main plate of armor, I could use my dremel to even out the edges so that it does not look like they were slapped on, but apart of the main torso armor (make it look like one piece of armor instead of three). Does that make sense? In my mind this idea works, but again, that is my mind. I have a gut feeling that it will not, so I am turning to you guys. What should I do? I do not want it to look like more than one piece of foam, but one piece. I do not know how to do that.