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Warhammer Chaos Knight Armor Made from Worbla

Chaos Knight costume 1

In case you need more proof that Worbla is one of the most versatile materials out there, please look at this Warhammer Chaos Knight build by Replica Props Forum (RPF) user Drack. He started working on the armor in January after acquiring some Worbla for Christmas. The middle section of the breastplate is expanding foam he carved into shape before applying Worbla to it, and there are so many details. This sort of armor lends itself nicely to using Worbla scraps – they can be reheated and shaped into the trim and other small, more intricate pieces.

The helmet was made from cardboard and then a thin foam. Drack sprayed expanding foam all around the foam structure of the cardboard and covered the holes in the expanding foam with more foam detailing before covering them with Worbla. He’s spent over $600 on Worbla for the armor so far.

Chaos Knight costume 2

Chaos Knight costume 3

Chaos Knight costume 4

Keep up with progress on the armor at The RPF.


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