How to Build a Foam Cosplay Helmet! (For Honor game)

For his E3 costume builds, Frank worked with foam fabricator Evil Ted Smith to make three awesome cosplay helmets. Ted joins us this week to show how he turns sheets of cheap floor foam into shapely sci-fi and fantasy helms. It's not too difficult!
Find more of Evil Ted's work here! eviltedsmith.com/
Shot and Edited by Joey Fameli
Music by Jinglepunks
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Tested is:
Adam Savage / donttrythis
Norman Chan / nchan
Simone Giertz / simonegiertz
Joey Fameli / joeyfameli
Adam Isaak / adamisaak
Kishore Hari / sciencequiche
Patrick Norton / patricknorton
Frank Ippolito / frankippolito
Sean Charlesworth / cworthdynamics
Jeremy Williams / jerware
Thanks for watching!
Learn more about For Honor. Watch the trailer here: • For Honor Trailer: Sto...
#FrankIppolito

[@tested]

Find more of Evil Ted's work here! eviltedsmith.com/

[@valkyrieace5768]

Wheres the best place to bye foam

[@jasonthompson7994]

Website is down

[@deepfriedsaltine3604]

@@valkyrieace5768 harbor freight sell it

[@AnimeBoyVFX]

Download pattern?

[@HottoysandHotCoffee]

Dude, can we appreciate the interviewer's questions? Every question was literally on my mind and he got me the answers, so massive appreciation for a proper selection of questions!

[@CookieBossTV]

Was thinking the exact same thing. So many times I watch interviews and the questions feel irrelevant or poorly informed. These questions were right on the money and enhanced the video endlessly.

[@GeorgeFelix-jv4fz]

Regardless of what you guys say, I think Norm is a great interviewer and commentator. He really pays attention to detail and knows how to direct the flow of the conversation.

[@aerobyrdable]

Historically I have not been a big fan of Norm, but he does a really good job in this one, and seems to have gotten better over time. All in all a great video with some really valuable tidbits

[@Veritias]

He's ok, but talks too much. Asking "yes/no"-questions get's boring in the long run and isn't a good quality in an interviewer..

[@Vogeluff]

i also think in this video he did a good job. but nonetheless, often , especially in convention floor interviews, he seems very awkward

[@7tqpbnvh7tqpbnvh77]

yes he is good. but sometimes he says things that is redundant. things that he asks and answers himself.

[@civiccc]

He also asskes all the noob questions we want to know!

[@Najvalsa]

The way he works so, for the lack of a better word, briskly, reminds me a lot of how Adam works. A cool guy and a cool build.

[@WarbandGamingOfficial]

Evil Ted is good people. He really does fantastic work. Check out the stuff he does on AWEtv.

[@EvilTedSmith]

Thank you. Check out my site eviltedsmith.com

[@richardrounce7138]

+Evil Ted Smith I visited your Web site and it's set up nicely, I found the helmet from this video and I wanted to make it but it's 5 dollars, if you could change it so it's free for a while I would love that thanks

[@bobrocks79]

Throw the guy a little support, it's worth it.

[@teph1256]

this guy is the bob ross of costume making

[@saltykenny1969]

Yes

[@martenj94]

I kid you not, I was just about to say the same thing!

[@Eleven7D7s]

hahahahahaha YAASSSS

[@ilijazz]

bob ross is the frank of painting

[@Arthurb06]

Man, you just hit the nail on the head.

[@lizvillegas6603]

I'm attempting a helmet for the first time, glad I found this video. :D I love how encouraging Mr. Smith is and how the presenter asked such specific questions.

[@redjack2629]

I'm totally with Ted. I love the anti-exclusive mindset of the prop and costume community. It's pretty rare that someone is trying to monopolize a technique.

[@EvilTedSmith]

Yes. When I started working in the effects world, there were a lot of people keeping secrets. It drove me crazy.

[@CRocketSlim]

We can't share enough info in the IT world... this keeping secrets mindset is alien to me

[@enisylo]

It's nice to see that there are areas where things are tending toward more openness rather than less, given the current climate of copyright and patent trolls.

[@tofuninja5489]

Sadly I've seen it with a few of the smaller members. Like someone who specializes in something and they really keep a tight lip on it because it's their bread and butter. However the bigger named community members are more than okay giving everyone their tips. I feel like it could just be the fact that they have less to lose than the smaller guys.

[@MrSolidBlakeGaming]

Red Jack then heroes workshop isn't for you xD

[@sheeesh833]

My toxic trait is thinking I can do this perfectly at the frist try for a cosplay I need to finish in less than a month

[@WilliamJakespeareProps]

yes! Evil Teds' on Tested! i use techniques I learned from him on nearly all my helmet builds!

[@TheLegoNewsReporter]

Hey Jake.

[@WilliamJakespeareProps]

Hey Project FIlmmaker!

[@casparvanhoute2366]

hey jake are you gonna do some more helmet tutos soon i love those ive made a wolverine cosplay cause you inspired me

[@WilliamJakespeareProps]

you know it! I just posted a helmet tutorial that combines techniques from Awe Me's DIY Prop Shop and Evil Ted! And there's another helmet tutorial that I'm hoping to have finished by Sunday

[@tr-8r721]

+William Jakespeare hey Jake it's me again love your work!!!!!!! awesome and thanks for posting that photo on Facebook for the star wars ray helmet. my cousin is going to a cosplay convention in Sweden. and he wanted to play as a male version as ray with the helmet. so thanks for that. your awesome!!!!!

[@CorneliusSneedley]

Wow, very informative, and it gave me a feeling of "Hey, I could do that." Very nice to watch with my morning coffee, thanks for posting.

[@Spidahjace316]

This guy just blew my cosplay mind. So much possibilities with this technique

[@sir_wesley86]

i CANNOT believe how well that glue works

[@normalrings5659]

Yeah def, its an industrial adhesive so it has to be really strong and barge, since its contact cement its really easy to apply and allows to make more curving pieces unlike glues like e-6000.

[@jessmac1893]

So is it just barge or something else?

[@normalrings5659]

ye its barge but its a contact cement, so if you cant find barge go look it up by that name

[@jessmac1893]

Ok, I was confused since he specifically called it drop and seemed to differentiate it from barge. Thanks.

[@the_arcanum]

The magic ingredient that makes Barge work so well, is its highly toxic toluene solvent. So wear a mask as you would if you were handling resin. This solvent has been mostly phased out in the EU because of safety issues. Too bad the substitutes are not as efficient. I just wish I was able to get some in Europe : those glue cans cannot be airmailed because of aircraft regulations :(

[@remain_]

Great job from the interviewer. Detailed questions really help us avoid making dumb mistakes.

[@gorillaau]

No such thing as a dumb mistake, but a chance to learn.

[@mumlee0127]

Loving the array of artists that are thrilled to share with others the tricks they learned the hard way. Beautiful as opposed to someone hell bent on keeping trade secrets secret.

[@mister_carrot8428]

I love watching how Evil Ted makes his armour pieces. so glad I subscribed to his channel. Now we just need to put him and Adam in a room together and see what crazyness they can make! :)

[@machzel08]

Norm, this was the perfect amount "ask a leading question, let the guy talk" A+ job

[@valleyDweller]

This is great. I've bought multiple books and been to multiple talks, but _watching_ him prep and bend with heat, and flipping it inside out were super motivating.

[@TamagoTamago77]

Ted is so cool and generous with his tips. Thanks Tested!

[@montelegaspi]

Again, Norm... Fantastic play by play questions and clarifications... Much love!

[@TheMuffin18]

I really like this dude. Makes stuff that looks intimidating from the outside become manageable and something anyone could accomplish. Really liking these tutorials.

[@borisdorofeev5602]

No matter how long you do something you never stop learning. Ted seems like a humble guy, the best kind of teachers are the ones that understand that they can learn from students too. Great stuff.

[@HackSawSees]

Evil Ted is really good on camera. Really nice piece, I tweeted this as maker friends. Thanks, guys!

[@alxdelrge]

This is fantastic. Thank you all for the work you do.

[@dhclark76]

Frank... you asked exactly all the questions I would be asking if I were there...which means I get to learn all the information that is usually lacking in other videos. That makes this video so much more useful. Thank you, thank you, thank you!

[@dakotascustomsful]

evil ted is absolutely my favorite person in the cosplay community. he frequents cosplay twitch streams just to pop in and see what your working on and tell you youre awesome. he is always happy to offer cosplay Senpai wisdoms if you ask him. just a genuinely good dude.

[@GadgetAddict]

That was awesome. I might try make one in a vlog.

[@jacobflynn9939]

Thanks for asking so many questions as he is working. I am a mere beginner so having him explain everything is extremely helpful.

[@NotTheLarryDavid]

This guy ROCKS. So passionate, curious and sharing... Go, Ted!

[@StephenOsirusCovers]

this was just straight inspiration for me. I'm almost ready to start making armor myself

[@k.3004]

Awesome! I'm thinking of making a space suit for a science project. Thanks for sharing!

[@AaronBlankenship]

Norm, you are getting great at interviews and questions. Keep it up!

[@lukav200]

Wow. Amazing video, amazing tutorial and amazing interview. I was interested the entire time by the crafting and the conversation. Keep it up guys!

[@CHIPNDEATH]

I believe we can do more not just helmets ,using this technique .. awesome

[@shinyandnotpanicking]

Evil Ted AND Tested in one video? YES.

[@rdoetjes]

Great video guys! I never realized it could be this simple and with such awesome results. I loved this peek around the corner into a costume/model shop.

[@carbon1255]

I love this format and this kind of hands on and like the level of advertisement especially of individual makers.

[@Cartoonman154]

I thought he was making magnetos helmet. lol

[@dyani1108]

that's why I clicked on the video

[@unknownfilms285]

Cartoonman154 it is a good design for his helmet

[@bloodyfx1065]

I mean, he wears a barbuta helmet and the helmet of the warden in for honor is a barbuta with a visor.

[@DETROITDEATHGOD]

I only clicked out of fear of mvc2 magneto flashbacks

[@adityawicaksono875]

What, he isn't?

[@markwilliams5654]

what a great guy thanks for sharing your knowledge with the world ;)

[@EvilTedSmith]

Thank you. Check out my site eviltedsmith.com

[@EvilTedSmith]

Whatever you want to wear.

[@gamingusa1536]

+Evil Ted Smith hey can you post a template for the helmet that you made and show how to make a visor for it like a knights helmet

[@EvilTedSmith]

I have the patten on my site eviltedsmith.com

[@5Perf65mm]

Great video. The questions Norm asked were very helpful.

[@CafeNFTs]

This looks like a ton of fun!! Thank you for showing us how to do this. About to hit the lab and create! 🔥🔥🔥🔥🔥🔥🔥🚀

[@jublywubly]

The foam is called EVA (ethylene vinyl acetate). The specific density that most gym mats are made from is known as EVA 75 in metric (75kg per cubic metre). I'm not sure how that translates to imperial. I presume it would be something like EVA 150 (150 pounds per cubic yard).

[@Rocker-tz2qk]

This is my dream job also. I Love this stuff it's so cool.

[@davestinyworkshopotherprojects]

I love this video, best tutorial on working with EVA that I've seen yet. I'm into my D-0 droid build now!

[@BradVilla]

So awesome to see Evil Ted Smith on Tested! After I put my costume together i will be sure to send a photo of it to Ted. Without him i wouldn't have completed it.

[@Lizity626]

Evil Ted also live streams on Twitch a few days a week! www.twitch.tv/eviltedsmith

[@FluffyVM]

mother of god... evil ted is a genius!

[@SteveMesker]

Really awesome video and very informative. Tested should definitely do more stuff with Evil Ted, the guy is fantastic!

[@EntropyBot]

Ha, already subscribed to Evil Ted! Great to see two groups I dig working together!

[@oszaszi]

OMG i used his vids before to make my armor :D and i improved a lot because he is approaching things easily and in cheap way without all that worbla shit which is super expensieve... he is the true mvp

[@ZoeyStarLady]

If anyone knows where I could find the template? It'd be perfect for the base of a Magneto helmet

[@mccoyisthebest]

i thought Magneto as soon as i saw it

[@ZoeyStarLady]

Never mind, just found his store! Can't wait to make some stuff

[@ZoeyStarLady]

+McCoyisTheBest it looks pretty much perfect for some of the most recent designs

[@HalCG]

eviltedsmith.com/downloads/basic-helmet/

[@AlbertoMartinez765]

Right!

[@elente]

One of the most useful videos i have seen on Tested... thanks!

[@Psychlist1972]

I'm always impressed they are able to sand and paint these so well. I would think foam would grab with sanding and wouldn't hold detail, so I never even considered working with foam. I really need to try this.

[@ninjapanties9631]

Evil Ted is the boss Ross of props

[@EvilTedSmith]

Ha ha Thank you.

[@3djooboy]

I know you mentioned the barge cement (flexible impact adhesive) asbeing the industry standard but what is in the "DROP" bottle? Is it the same stuff? I have used barge before but never from a squeezy bottle.

[@amandaalvarado9959]

Did anyone answer this? :/

[@joninfect8681]

amanda alvarado no... but I'm waiting =P

[@Zharick.407]

@@-Diana469 He specifically differentiates DROP from Barge at around 10:05 so they're different, but I can't find anything online about the DROP glue :(

[@samuelmenicucci5234]

This is great! I'm just starting to get into cosplay and this helps so much!

[@jonathanwiggill8242]

Ted, What a great guy. Encouraging Tutorial. Thank You.

[@MrDarling1502]

It would be awesome if you guys linked to actual materials used.

[@mccallcarlson3580]

Floor saver mats available at any hardware store, the glue is called "Drop" I think it's a brand name.

[@paulhudson6846]

So i guess this channel is becoming Evil TesTED

[@paulhudson6846]

Im never going to comment a pun again. Im sorry.

[@Hamatabo]

+CrudeGamer and brimstone?

[@paulhudson6846]

CrudeGamer my mixtape is coming in august dont worry ;)

[@gorillaau]

@@paulhudson6846 I laughed. :-)

[@uninter3sting]

I'm going to be cosplaying a character w a helmet soon and I can't find it online anywhere to purchase so I decided I'll make it. This is so helpful!! I'm excited to start working on it now I've never made my own cosplays

[@amaiandreaper4113]

Thank you so much for this. I'm working on a cosplay for the game "Hyper Light Drifter", so this really helps with learning how to make the helmet! :)

[@luannas.230]

2:30 where can i download that? Please someone tell me.

[@codycrawford4579]

Evil Ted doesn't seem very Evil...

[@normalrings5659]

thats what he wants you to think

[@TimShredder]

Not evil at all, comes across as a positive guy willing to share his techniques.

[@EvilTedSmith]

Thanks.

[@MajesticJoy19]

Yeah, you can say that.... I mean... someone here just call him "The Bob Ross of costume making".... THE BOB ROSS!! you know what's that?!.... like, if you were rape 'till almost dead by Hulk and Thanos at the same time.... Bob Ross would make you forget all about it by just singing twinkle twinkle little star while drawing little bushes were little happy rabbits live

[@incree25]

Love the videos from Frank's shop! Nice tutorial, short but good content. Gonna take a look a this guy's work. Thx!

[@hhipis]

EvilTed! Congratulations! Love your channel! And Tested!

[@gordontarpley]

TED!

[@ranwolf76]

we will ride through the gates of valhalla shiny and foam

[@EvilTedSmith]

Yes shiny and foam forever...

[@--_V_--]

That weathering is amazing

[@ok1moretime]

Im so glad you put the helmet on at the end :). Awesome works.

[@nathantron]

Where is the link to that guys channel? Why is nobody getting credited anymore on youtube, its horrible.

[@lucasboisneau4256]

evil Ted Smith

[@Zhyrca]

It's in the description section at "Collaborator" and click on "Evil Ted Smith"

[@Exevium]

Agreed. I want the old KZbin back.

[@lawlypooper]

Tell me 'bout it -- They only plugged both his website and channel. Fucking pirates.

[@Exevium]

TOTAL Norm only said he had a KZbin channel, he never asked about the name of it. He had to plug it himself, which makes it seem selfish, when in fact it's Norms job to make sure his name is in this vid.

[@savannahseaver7492]

can you use a blow dryer instead of a heat gun....

[@MrMassmahem]

No not hot enough

[@EvilTedSmith]

Yeah, you need a heat gun.

[@epicsaxguydave9018]

Yes

[@arthurguseynov7167]

I think so

[@unbearablyunjoyable496]

Savannah Seaver yes... I did so you can too, but it doesn't have as good affect as a heat gun

[@Tron08]

This is great! Just in time for me as we're already planning our Halloween costumes that may need some foam accessories. I eagerly await the finishing/painting tutorials to come!

[@williamsramos8779]

loving your work

[@CivicWitThaCivic]

That guy reminds me of Adam

[@cdp200442]

what glue is he using ?

[@YeahWhatSon]

he says it in the video, it's Barge glue

[@amandaalvarado9959]

He said that was his favorite but is it what he's using?

[@NathanLy66]

u can use contact cement it works really good with foam

[@AlbertoMartinez765]

Love EvilTed! I learned so much from this video looking forward to the others!

[@dmagginnis]

This is awesome! I learned how to work with EVA foam by watching Evil Ted's KZbin videos!

[@danielmiskoidea]

:)

[@demonwarrior6968]

Ted: i love sharing Also ted: template is 5$

[@stirfry4751]

Gotta support his hobby somehow

[@demonwarrior6968]

@@stirfry4751 i guess

[@someguardsman]

At least he made it something that you could have access to. It's a fair price for a template like this, the foam itself that you work with costs more.

[@Brakzillaa]

Well, $7, now lol

[@enzoyin1451]

FINALLY! TESTED PLS MORE EVIL TED FEATURES

[@yshrenianknight2516]

This is one of my favorite designs ever. This is the Visored Barbuta Helmet

[@josejn2007]

Hi! Where can I download the helmet blueprint?

[@MeeVivii]

josejn2007 I KNOW IM LOOKING FOR IT TOO

[@battleaxebob45]

For Honor Foam Armor. Say that 10x fast.

[@C00T47]

FUCK!

[@OnesieGamingJessica]

thank you so much for sharing this! its the best tutorial I've watched! this year I've decided to start and create my own cosplay and my first attempt is actually going to be the female version of the viking in for honor!!!!

[@funkycowie]

I was using those techniques 25 years ago when I was doing LARP... it's interesting the same techniques are being used now for cosplay.

[@UnstoppableForceProductions]

Ok, I love it, but where the HELL do you get a pack of foam like that for $9.99????

[@thomasnewsome5923]

Harbor Freight tools, my dude.

[@TestarossaF110]

I expected X-men I'm disappointed.... :((

[@pguth98]

Disappoin...TED?

[@mablestark6501]

+Peter Guthrie that was good! high five Peter!

[@seal1731]

+Peter Guthrie hue

[@jounger]

Magento :))

[@eskrape]

Evil Ted Smith is the godfather of foam! 😍 such an awesome guy!!!

[@Cestacular]

Thanks Evil Ted, great to meet you!

[@EvilTedSmith]

Thank you.

[@eringilchrist7583]

Anyone here for Voltron cosplay??

[@TheBelgianTerror]

Great video! What would be nice is that Norm would simultaneously build one of his own. Then you could see the result of a noob. Also you could adres some problems that wouldn't come to a pro's mind. And it would also be fun to watch!

[@172-0]

This was so informative! I learned so much thanks.

[@EmmettMcMullan]

I thought that was evil ted! Love his channel

[@AlleyBetwixt]

Excellent demo!

[@KillingDeWars]

This is excellent. I'm building my first cosplay and this video taught me a shit tonne. Definitely subbing to Evil Ted.

[@geordiekimbo2]

Holy cow, there's TED SMITH. Awesome.

[@GaMeMaNiAc248]

We need more of this guy on tested!!!

[@rilakumacakerolls9094]

I love the reaction of Norman on the horns! Like a kid.

[@light487]

Ordered template today, picked up all the materials. Will give it a crack tomorrow. Although I couldn't get barge or weldwood. They were very expensive. Hoping the other rubber cement works well enough for my kids.

[@foist101]

I love the attitude of "never stop learning" Evil Ted and Tested in general has, even though many would consider him and others on the show experts. I came from the Source modding community where most people are self taught 3d artists and animators, and unfortunately it breeds an incredibly arrogant attitude where people shun any kind of learning or sharing of information.I can't wait to see more from Ted here in the future!

[@RobertAniFreak]

I love the viking helm with horns, It looks pretty amazing with the details

[@MiniDemonic]

Fun fact: Viking helmets did not have horns. That's a myth.

[@RobertAniFreak]

MiniDemonic Awww T-T Thats a bummer

[@Tensen01]

Fun Fact, it's a fantasy helmet, so it doesn't matter

[@killax1000]

Funner Fact: When Wagner staged his “Der Ring des Nibelungen” opera cycle in the 1870s, costume designer Carl Emil Doepler created horned helmets for the Viking characters, and an enduring stereotype was born