What type of foam to use?

[ladman]

I have been kind of in a hard spot here. I am trying to figure out which way to go with foam for my iron man suit. I have heard of people using 1/4" to 1/2". my question here is what thickness to use on parts of the suit.

I have tried cardboard, but that left an undesirable look to it. I recently bought 1/8 yoga mat, but that was too floppy.

I thought about using 1/4 inch EVA interlocking foam mat from home depot? Here is a link to that product:

Coin Black 20.5 in. x 20.5 in. Residential & Commercial Interlocking Multi-Purpose Flooring Tile, 8 Tiles-0053845 at The Home Depot

I have even seen some people say they order it form foamorder.com

What should be used on a helmet? 1/4" and the rest of the suit 1/8?

 

[daninboo]

Your going to want to use all thicknesses eva foam mats. For the helmet use the thinner stuff cuz it bends easier

 

[ladman]

The helmet wont be too floppy with a thinner foam? when i put the PVA on to seal it, im guessing it will become denser.

Im guessing that using thinner on the rest of the suit if for showing more detail in pieces and use thicker for the over all structure of the piece?

 

[IMIM2]

If it is too floppy, double it AFTER you finish the helmet.
Do not double it before.
Or you can glue some foam "strips" on the inside for structure.

 

[Lflank]

I like all my armors and costumes to be lightweight, so I use 1/4 inch craft foam (from Joannes or Michaels) for almost everything (parts that are mostly rounded, such as helmets, are easier to make with 1/8 inch foamies).

I usually stiffen and harden my foamies pieces by cutting a piece of plain cotton muslin cloth and layering that on the inside surface with PVA white glue. It stiffens the pieces nicely, but still leaves them lightweight. And of course I also coat the front surface of the foamies parts with PVA, to seal it, help stiffen it, and leave a paintable surface.

Anyway, that's how I do it. Your mileage may vary.

 

[wondersquid]

I make all my suits out of a combination of all the foams, if you can get your hands on them you want everything from 1/8" all the way up to 1/2" inch thick. Generally the helmet is 1/4" because you want it lightweight, you can stiffen the foam by layering it. For example, on my mark 7 helmet I made it from 1/4", but on the sides I glued on detail sections with 1/8" and that made the sides sturdy. Also when building, your construction methods help to create sturdy shapes. Often I use 1/2" floor mats from harbor freight for the chest, back, shoes, waist and lower legs. Then I glue detail layers in 1/4" and 1/8" to create the whole final look. This all helps to stiffen the foam before you PVA, just don't have unreal expectations of the foam, it will never be as stiff as plastic or fiberglass. Good luck!

Sent from my DROID BIONIC using Tapatalk 2

 

[daninboo]

Well said wondersquid, if you can get it, get it cuz you will use it. Its not an exact science, find a method that works for you and work at it, just like anything else the more you do the better you get

 

[ladman]

Great information here guys. Looks like i have a lot of foam to purchase to keep on hand for various tasks and layers.