Redditor emilschm, a.k.a. Emily, is working on her first all foam costume build, and she’s going all out. She shared an in-progress picture of her Warhammer 40K Sisters of Battle armor made from multi-colored pieces of foam and googly eyes (they make excellent bases to simulate rivets). It looks like an intricate puzzle, and amazingly, the armor shown in this photo took just two weeks to cut and assemble. I realize she’s going to paint the finished outfit, but it would be sort of fun to leave in rainbow form. She shared the basics of making the armor:
You have to use contact cement to connect the foam pieces together. You apply this to both sides, let cure, and then attach. The foam is the base of the armor and you build in layers. The foam comes in different thicknesses but people generally use L200 and you can order it from tntcosplaysupplies.com It’s relatively light considering other options but can be hot in the sun or after long periods of wear. Before you paint you seal the foam with plastidip and it becomes like rubber. Then you can paint with spray paint and brush on acrylics, and yes deco art metallics are good for this.
You can see more photos of the build by following Emily on Instagram.