Recommended EVA thickness for Armor builds

[HeroOfThePeople]

Hello everyone,

I've been costuming for a while, mostly sewing and leatherwork (I may throw up a post on my Green Arrow at some point) and have decided I'd like to learn EVA foam armor construction for future projects.

I see this as a skill with nearly limitless application, but for my first project I think I've decided on the less ambitious Mass Effect N7 armor, likely to be followed with an Iron Man armor (which iteration remains to be decided). I've found plenty of options to source EVA but what I'm wondering is what thicknesses do people like to work with so I'd like to take an informal pole.

What thickness are you working with for your foam armor builds, what have you worked with in the past, what do you like about it, what do you dislike?

Thanks,

HeroOfThePeopel

 

[XRobots]

I used 10mm for all, generally most people say not less than 6mm, not more than 12mm. Although you could use thinner foam in layers for details: XRobots.co.uk - Iron Man MkVI Armour Foam Building

 

[HeroOfThePeople]

Thanks XRobots. I've watched most of your youtube tutorials and build logs as research before deciding I wanted to try my hand at foam. You do excellent work.

Funny you should mention them, the three thicknesses I'd considered are 6mm, 10mm and 12mm but don't know where to start with deciding between them. I'm pretty sure that with practice any of them could result in a superb set of armor, but I hate wasting materials through my lack of skill. I recognize failure is a part of the learning process and know I'm likely to screw at least a few things up along the way, but would like to keep that to a minimum. Do you think any particular thickness is more forgiving and newbie friendly?

My hypothesis without actually working with them is that 6mm molds more easily with less time under the heat gun but is more susceptible to melting and other heat damage, and because the bonded surfaces have smaller cross sections and therefore less surface area getting good bonds with the hot glue may be harder. Also it would be more flexible which might reduce the illusion of rigid armor. 12mm, I assume would have the inverse problems, harder to mold, and perhaps too bulky.

Keep the feedback coming. I'm probably a month away from starting any builds and definitely in a research phase.

 

[msleeper]

Unless you'll be wearing your costume in Death Valley, then I wouldn't worry about it melting or being damaged by heat while you're wearing it. Most people who have their costume "melt" leave it in a car in the sun and yeah, that will absolutely destroy foam. Been there, done that.

 

[HeroOfThePeople]

By melt I meant during the forming process, while under the heat gun. My assumption is with 6mm if you mistakenly pause your heat gun in one spot for a few seconds you could damage the foam. Regular everyday environmental heat isn't going to do anything to a suit, unless as you say you leave it in a closed car in direct sunlight, worst case your glue will soften in the heat before your foam would melt.

 

[msleeper]

"A few seconds" shouldn't do anything bad. It might wrinkle the surface a little, but it's not going to slag it or anything unless you're really careless. Which you shouldn't be, most heatguns can get incredibly, ruin-your-life hot.

 

[HeroOfThePeople]

I have a bit of personal experience with the danger of heat guns... Many years ago I once ignited a piece of canvas while attempting to impregnate the fibers with a wax/solvent/linseed oil blend to make oilcloth.

Also what temp are most people setting their heat guns to when heating foam, mine can range from 250f to 1200f.

 

[LordCaharin]

Now stupid question time, so the anti-fatigue mats that come in the packs of 4 are usually the 10mm, the ones that come in the rolls are 6mm and of course craft foam from the regular stores (walmart, etc.) are smaller mms?

 

[HeroOfThePeople]

It depends, lots of manufacturers with lots of variety. I've seen mats marketed as anti-fatigue mats in all three thicknesses I mention in the OP. 6mm, 10mm, and 12mm if you're more comfortable with imperial measurements those are approximately 1/4", 3/8" and 1/2" respectively. And you can find these in hardware stores or sporting good stores as floor mats, or fairly small rolls or often more economically you can buy it by the larger roll online.

Craft foam that you might find in a hobby shop, like the "Foamies" brand is generally 2mm or 4mm and sold in 8.5"x11" or 11"x17" sheets.

 

[LordCaharin]

It depends, lots of manufacturers with lots of variety. I've seen mats marketed as anti-fatigue mats in all three thicknesses I mention in the OP. 6mm, 10mm, and 12mm if you're more comfortable with imperial measurements those are approximately 1/4", 3/8" and 1/2" respectively. And you can find these in hardware stores or sporting good stores as floor mats, or fairly small rolls or often more economically you can buy it by the larger roll online.

Craft foam that you might find in a hobby shop, like the "Foamies" brand is generally 2mm or 4mm and sold in 8.5"x11" or 11"x17" sheets.

Imperial measurements....I like the sound of that. And thanks, I was never sure half the time what was what.