How to Make Your Own Cosplay Costume Armor

Costume armor is an excellent way to add some realistic detail to your costumes. You can use a few basic materials to create lightweight, flexible armor that looks like it’s been worn for years. This article will guide you through making a set of armor pieces for your next cosplay project using craft foam, heat, and glue. It will also cover how to paint your armor so that it looks more authentic.

First, take some measurements of the person wearing the costume. This will help you figure out the size of the head, chest, arms and legs so that your armor fits well. Once you have all of the measurements, you can create a template to work from. You can do this by hand, or you can use a computer program that can do it for you (like Pepakura). After your pattern is finished, check to make sure that all the parts have been accounted for and that there are no duplicates. Once everything is accounted for, clean up your design and cut all of the pieces.

When you’re ready to start putting the pieces together, get some high temp hot glue sticks and start gluing everything in place. Once everything is dry, you can smooth out any excess glue with a blade or a file. Once you’ve done this, take a spray can of Plasti Dip and coat all of your armor (the side that will be shown). Let this dry for a day before you start working on the details.