Oh. I was thinking that Bondo may work, but I've never actually used it before so I'm not sure how well it would work with the foam. Either that or maybe fiberglass.
Thanks. I did a lot of searching on this board for information before I started.
There is mostly no reinforcing and rely on the layers of foam to hold itself together. In some high stress areas (joints) where tearing could occur, I hot glued some fabric onto the back of the foam.
Mod Podge is used to seal the surface of the foam to give it a smooth finish before painting with a flexible paint. It doesn't really add any strength to the foam.
What a great read and compliments on how documented the whole thing. Thanks for posting this. I am an animator, and I worked on the movie animating the lightbikes, light jets and the disc battle shots. I love seeing peoples interpretations of the costumes and props.
Awesome work.
Here are some pics of me with the actual practical Rinzler disc used in the movie...
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Steve,
You mentioned awhile back you watered down your mod podge, and used several coats of it on your foam (plus plastidip) to achieve the awesome look your costume has. Did you actually measure each part water and mod podge, or did you just add water to the bottle?