Means of attaching EVA foam to aluminum frame?

Discussion in 'Replica Costumes' started by Marthony, May 28, 2015.

  1. Marthony

    Marthony Active Member

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    Hello,

    I plan to build a stilted G1 Transformers Devastator costume, and for the torso I plan to build a suspender & hip belt supported 3/4" square aluminum tubing frame. I plan to make the detail of the costume with EVA foam, but would like options for rigging the foam to the frame.

    Picture reference: http://i1276.photobucket.com/albums/...ps1tysoxul.jpg

    Vertical proportion: http://i1276.photobucket.com/albums/...psn2rgljtk.jpg (minus 3" on the risers)

    Initial torso diagram: http://i1276.photobucket.com/albums/...pst7zdz0ou.jpg My groin to 1" above my head is within the torso.

    I can drill holes for bolts anywhere in the square tubing. For +1 layers for foam I know I could bolt the foam to the frame & hot glue layers to that...

    How might you approach it?

    Thanks!
     
  2. gothic

    gothic Sr Member

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    never tried anything large scale but If you rough the surface of the aluminum and rough the other side of the foam and use contact cement the foam should stick, try some test pieces, its worth a try :unsure
     
  3. fallimar

    fallimar Well-Known Member RPF PREMIUM MEMBER

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    This is exactly the advice I was going to give. Contact cement is amazing for what it'll hold. Roughed-up metal holds beautifully and the bond it makes with foam is stronger than the foam itself. Great stuff.
     
  4. Marthony

    Marthony Active Member

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    Interesting! I wouldn't have thought of this.

    I certainly have options for roughing it up; once with heavy sandpaper and then some cross-hatching with a Dremel tool...

    I might be tempted to reinforce the most important contacts with nylon straps for example, just to feel more secure about it. I'll give this a try.

    Any particular brand of contact cement you'd recommend?

    Thanks!
     
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  5. gothic

    gothic Sr Member

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    No prob i do the same attaching plastic to foam i sand the surface then cross hatch it. your probably better cross hatching with an exacto/craft knife, dremmels are great but hard to control for fine work. also your using aluminum its going to be hard to join plastic box sections are light and you can join them easier with angle joints or glue the joints. good luck with the project look forward to the postings :)
     
  6. gothic

    gothic Sr Member

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    sorry didnt see the question about the glue, i use EVO-STICK contact cement you can buy it in tins or in tubes, the best is supposed to be BARGE contact cement but its not easy to find outside of the U.S.A
     

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