Tip on making seamless seams with EVA foam.

Discussion in 'Replica Costumes' started by familyman, Mar 28, 2012.

  1. familyman

    familyman Sr Member

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    Hi there. I am busy making some costumes and props with EVA foam. I know some people (myself included) have had some trouble with getting the seemless look when gluing two pieces of foam together. Today I thought I would try something out and it work.
    Here is what I did, I hope it will be of use to some.

    First, get the two pieces of foam you need to glue and lay them face side up next to each other. Then using clear tape, tape them together.
    [​IMG]
    Then turn them over making sure to keep them taped nice and close. Put hot glue right in the seem and then some along the edge.
    [​IMG]
    Fold the pieces to the angle you need and hold for a few seconds until dry.
    [​IMG]
    Here is the outside of the two pieces you see the tape is still keeping the pieces together.
    [​IMG]
    Once dry remove the tape and you should have seems like these.
    [​IMG]
    [​IMG]

    Enjoy and good luck with your future seems.
     
    hydin likes this.
  2. ReplicaGod

    ReplicaGod New Member

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    Re: Tip on making seemless seems with EVA foam.

    Thanks for the tutorial, I'm sure this will be of help to foam armor people. Even though they still use plastidip.
     
  3. SChristides

    SChristides New Member

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    Re: Tip on making seemless seems with EVA foam.

    Welcome bit of advice =) thanks you very much sir
     
  4. Judge Spartan

    Judge Spartan Sr Member

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    Re: Tip on making seemless seems with EVA foam.

    Great tutorial Jamie, thanks..
     
  5. Deelite

    Deelite Active Member

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    Re: Tip on making seemless seems with EVA foam.

    thanks for sharing. Somewhat of a similar method I'm doing for seams on my foam builds.
     
  6. Loogie

    Loogie New Member

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    Re: Tip on making seemless seems with EVA foam.

    wow thanks for the quick lesson :cheers to u sir


    Loogie
     
  7. propnoob74

    propnoob74 Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    Awesome!!!!! I'm going to use the tip! you are the best!!!
     
  8. Raithan

    Raithan New Member

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    Re: Tip on making seemless seems with EVA foam.

    Thanks for the great tip. Starting my first foam helmet this weekend. This is going to help a lot.
     
  9. InsaneLuck

    InsaneLuck Member

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    Re: Tip on making seemless seems with EVA foam.

    thanks for the tip
     
  10. Joshturismo

    Joshturismo New Member

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    Re: Tip on making seemless seems with EVA foam.

    thanks for the tip im going to try this.
     
  11. mxpxrobbie

    mxpxrobbie Active Member

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    Re: Tip on making seemless seems with EVA foam.

    Going to try this out... looks great! Thanks for the tip!
     
  12. pwrofbauer

    pwrofbauer Active Member

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    Re: Tip on making seemless seems with EVA foam.

    This is super helpful! Thanks!
     
  13. cavedwellar

    cavedwellar Sr Member

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    Re: Tip on making seemless seems with EVA foam.

    Great tip!
     
  14. animefan

    animefan Sr Member RPF PREMIUM MEMBER

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    Re: Tip on making seemless seems with EVA foam.

    great idea man, i will try this out.
     
  15. bhodie

    bhodie Active Member

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    Re: Tip on making seemless seems with EVA foam.

    NICE! Great tip!
     
  16. cama900

    cama900 Active Member

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    Re: Tip on making seemless seems with EVA foam.

    That is AWESOME! Thanks!
     
  17. Jessica

    Jessica Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    wow. thank you for the great tip!
     
  18. MychoPsantis

    MychoPsantis New Member

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    Re: Tip on making seemless seems with EVA foam.

    Simple and effective idea. Definitely going to put it to use. Thanks!
     
  19. b9er

    b9er New Member

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    Re: Tip on making seemless seems with EVA foam.

    This was a great post thanks !
     
  20. familyman

    familyman Sr Member

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    Re: Tip on making seemless seems with EVA foam.

    You guys are very welcome.
     
  21. Grave

    Grave Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    SOB! why the H did i think of that!
    awesome, thanks for the tip.
     
  22. AdamJ

    AdamJ Member

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    Re: Tip on making seemless seems with EVA foam.

    Awesome tip, one i shall be using, thanks very much !
     
  23. dkuan37

    dkuan37 New Member

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    Re: Tip on making seemless seems with EVA foam.

    this is good to know, thanks so much for sharing!
     
  24. lharles

    lharles Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    I may just take on an R2 build like yours, with information like this. :) Thanks!
     
  25. Mig407

    Mig407 Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    very cool trick!
     
  26. doc

    doc Active Member

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    Re: Tip on making seemless seems with EVA foam.

    Those are some clean fold lines. Thanks for the help
     
  27. Piraterogue

    Piraterogue New Member

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    Re: Tip on making seemless seems with EVA foam.

    How did you figure out this trick? I would never have tried the tape trick.
     
  28. familyman

    familyman Sr Member

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    Re: Tip on making seemless seems with EVA foam.

    Simple, I ran out of hands. lol. Nah honestly it just came to me.
     
  29. crabra comander

    crabra comander Sr Member

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    Re: Tip on making seemless seems with EVA foam.

    Great tip, simple process for builder Noob like me!
     
  30. Nintendophile

    Nintendophile New Member

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    Re: Tip on making seemless seems with EVA foam.

    Awesome tip! But, I'm confused as to how the outside seam is staying together and not pulling apart. Do you put hot glue down INSIDE the seam as well?
     
  31. gazza554

    gazza554 New Member

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    Re: Tip on making seemless seems with EVA foam.

    awesome tip! thanks! i will be trying this out when i get back out my iron man armor build :)
     
  32. n0regret5

    n0regret5 Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    seam seam seam seam seam seam seam seam seam seam seam seam seam seam seam seam seam seam seam seam!!!

    thanks for the awesome tip though. my last project had a few tight corners and I could never get them quite close enough. this will work great! :D
     
  33. familyman

    familyman Sr Member

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    Re: Tip on making seemless seems with EVA foam.


    Yes I lay some hot glue right in the seam,
    [​IMG]
     
  34. batbassi

    batbassi Member

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    Re: Tip on making seemless seems with EVA foam.

    Are you cutting at a 45 degree angle on the backside?
     
  35. Nintendophile

    Nintendophile New Member

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    Re: Tip on making seemless seems with EVA foam.

    I think I get it now. It was a little confusing in the picture. Thank you for the clarification! ^_^

    Ohhh, yeah, it looks like it is cut at a 45 degree angle! That's what I didn't notice before. It looked like his seams were butted up right against each other, with only a bead of glue on top of the seam. But, now that I look at the bottom part of the picture, at the end of the seam, it looks like there's a slight "v" cut to it. That makes a lot more sense.
     
  36. familyman

    familyman Sr Member

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    Re: Tip on making seemless seems with EVA foam.

    Ok sorry let me try and clear things a bit yes, in the pick the two pieces of foam are cut at a 45 degree angle, it is the best way to get smooth seams and edges rather then just glueing one piece flat against another piece to get a right angle. However.. I have also used this technique to glue two long pieces of foam together to make an even longer piece.
     
  37. Indigogyre

    Indigogyre Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    Cool, I've known about this type of thing for putting together miters in woodworking but never thought to use it on foam!

    One other idea that might work excellently with this for when two pieces join at a 90 is to cut one at a slight 89 degree bevel from front to back. This will insure that the front edge touches perfectly and thus creating smaller seams also.

    Now to find some low tack clear tape!

    Dean
     
  38. Grave

    Grave Well-Known Member

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    Re: Tip on making seemless seems with EVA foam.

    green painters tape works well
     
  39. familyman

    familyman Sr Member

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    Re: Tip on making seemless seems with EVA foam.

    The main reason I like cutting at 45 is because you not only get a nice seam but you also get nice smooth edges. Sometimes if you don't cut the foam smooth enought the rough edge can look awfull.
     
  40. McAullay

    McAullay New Member

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    Excellent advice. Is there any extra advice you could offer as to the taping and gluing when the pieces are rounded and forming contours when glued. I'm mainly thinking about the Ironman helmet pieces where angled cuts of a single piece are glued together rounding the piece.
     
  41. familyman

    familyman Sr Member

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    I have found using scrap pieces of card can help. What I do is make sure the glue gun is nice and hot so the glue is very runny, spread a small amount on the edge I am currently working on and then using a scrap piece of card I spread the gluealong the edge I am glueing getting it thin and close to the edge. Then quickly press the other piece of foam to the glued area. Makes a nice even seam that is glued right to the edge. Wipe any and all glue that might ease through. What part of the Ironman helmet are you working on. I have completed several ironman helmets out of foam and might be able to help you out more.
     
  42. Kolin86

    Kolin86 Active Member

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    Got to try this out rebuilding the thigh pieces for my costume. Your tip was a godsend! They are much cleaner now, thank you.
     
    tsam likes this.
  43. ValTroX

    ValTroX New Member

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    Great tip, I'm waiting on my mat cutter to cut the angles(i seem to be VERY bad with scissors) and this will come in handy when putting the pieces together.
     
  44. familyman

    familyman Sr Member

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    You are most welcome.
     
  45. CaptainVermont

    CaptainVermont New Member

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    Wow... that's a fantastic looking seam. I was trying to figure out exactly how to do it, and you nailed it. Hopefully I'll get some build posts up by the end of this weekend!
     
  46. DarthVeach

    DarthVeach Well-Known Member

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    This is a great tip!! This will help me a lot.

    What size blade are you using to cut the thicker foam like this?
     
  47. jackDroid

    jackDroid New Member

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    @familyman - awesome tip! Plus using the clear tape lets you really see how your finished edge is coming together. Am a bit curious if youve ever had a problem with the tape trying to tear at the foam when removing? Whats your preferred brand?

    Thamks for sharing.

    -jon
    jackDroid
     
  48. familyman

    familyman Sr Member

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    Thanks man. With regards to your question, I have never had a problem with the tape tearing the foam. I almost did once, but just easing the tape past the area that was troublesome easily fixed that. As for preffered brand, I get the cheapest I can find. Normaly it is around $1 - $2 for 4 - 6 rolls of ultr clear from dollar stores.
     
  49. lunar lord

    lunar lord New Member

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    the pictures are broken :(
     
  50. familyman

    familyman Sr Member

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    Yeah sorry my photobucket bandwidth has reached its limitis until the 23rd.
     

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