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Make a Foam Armor Chest Plate 3


In this part of the tutorial we finish the making of the chest plate. On the next page we will paint it.

Part 1 of this tutorial is here



Glue the foam to the sheet

Carefully and evenly apply the foam sheet to your adhesive treated armor piece. A good way to do it is right along the centerline of the armor. This will help to give it a good look when it is done. And most of the seam will be hidden.

Press it evenly and smoothly. You want nice and complete gluing between the foam sheet and the posterboard. Otherwise your foam might bubble when you paint it.

Work carefully with the foam. Try not to get any adhesive on the top surface of it. It will change how it looks when painted.


Match the edges

Now Continue applying foam, keeping the seems nice and tight. Two sheets of foam covers almost the whole thing for me. See tthat little triangle of poster board still sticking out? I cut a piece of foam and glue it right over that. Cover the whole chest piece in this matter.


Trim the foam

Flip it over so the posterboard is up. And trim off all the excess foam.


Repeat the process

Repeat this same process with the other half. Now you have your armor. This is the bulk of it. Simply two pieces, a front and a back.

Notice that these two pieces are different. There is a back and a front!

Now let's apply velcro to the pieces so they can be assembled together and worn.

Let's start with the back piece.

On the back piece we are applying four pieces of velcro. And we are applying it to the foam side of the piece -not the posterboard side.


Apply velcro


Now apply the mating pieces of velcro to the other piece of armor. This is the back of the armor. And importantly we are applying the velcro strips to the posterboard not to the foam! You will see how this works when you put it on. Apply the strips of velcro in the four spots shown by the black lines.


Apply Mating velcro


Add details

Now cut some foam pieces and glue them as details on the chest piece. You have a whole lot of freedom as to how you do this.

Add more details

Here is the detail work that I applied to the front. 1 thru 4 are the edging. And 5 is the center piece right in the middle of the chest.

Do the same thing for the back piece of the armor.

Let's finish it off by painting it



Make Craft Foam Armor Vambraces (Forearms)

Craft foam is some terrific stuff. You can heat it up and shape it into armor. I show you how in this tutorial and I give you the template to make vambraces. Make Craft foam vambraces



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