STEPS
SKILL LEVEL
by Dremel ®
226 PROJECTS
Tools & Accessories
Materials
-
1
Printed Pattern -
3
EVA Foam: 1cm, 5mm, and 2mm thick -
1
Craft Knife -
1
Cutting Mat -
1
Whiteboard Marker -
1
Contact Glue -
1
Stirrer -
1
Heat Gun -
1
Heat Gun -
1
Heat-resistant gloves -
1
Safety Goggles -
1
Dust Mask -
1
Clamp -
1
primer -
1
foam brush -
1
Airbrush -
1
paint
Let's Get Started
To reduce the risk of injury user must read instruction manuals for all tools used in this project. Wear eye and respiratory protection. Use clamps to support work piece whenever practical.
Trace the pattern onto EVA foam and cut it out
Start this exciting, easy cosplay project by downloading your chosen cosplay helmet pattern. Our Master Maker, Wayne, bought his in Evil Ted Smith's online shop - he chose a basic EVA foam helmet template built up out of four individual sections. Trace the parts with a whiteboard marker onto a 1 cm thick EVA foam sheet. Place the foam on a cutting mat and, using a craft knife, cut out all the different parts. Watch your fingers and hands! EVA foam blunts the knife quite quickly, so make sure you sharpen it when needed.
Glue together your basic foam helmet
It's time to bring out the contact glue - Wayne uses a refillable plastic bottle, making the glue easy to apply. Squeeze a thin line of glue along the two edges you want to glue together. Spread the glue into a thin layer using a wooden coffee stirrer, then allow it to dry for 10-20 minutes. Meanwhile, mark up the chin piece with a line, insert the knife halfway into the foam at a 45-degree angle and cut along the line on both sides to make a groove. This will create a sharp edge later. Now press the glue-covered edges together, bending the foam as you go. Repeat for all other edges that need gluing.
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