How to Make Male Foam Cosplay Armor, Tutorial Part 2

[@DeadEye428]

This man is a genius. Every little trick alleviates a mountain of headache

[@EvilTedSmith]

Thank you for watching and subscribing.

[@jonathanblaine4121]

I love the transformation it goes through during the plastic sealing. From "pretty darn neat looking foam armor" to "$$$ Hollywood film prop". And it hasn't even been painted yet. Awesome work.

[@EvilTedSmith]

Jonathan Blaine Thanks Jonathan for kind words and subscribing.

[@pocketninja2506]

Please remake part 1. I almost didn't hang in there for part 2, but I'm so glad I did. You really have my wheels turning. I'm eyeballing my foam board with a new, evil glee!

[@ilovfob]

You've inspired me to create things out of foam. My eventual goal is to do deadric armour from skyrim and power armour from fallout.

[@EvilTedSmith]

+Hylian Ruler Sounds fun.

[@GT-wj3gl]

How did that turn out? I'm thinking about doing that armor too but I'm really nervous that'll I'll just end up screwing it up and wasting money.

[@Leppy101]

If you're just starting out, be prepared to make a lot of mistakes. DON'T BE DISCOURAGED. You're not going to make a perfect cosplay piece the first time. You'll learn as you go. The more you practice and work on your cosplay builds, the more techniques you'll learn to make a better end build. As long as you learn from it, it's never a waste of money.

[@WateryIce54321]

I'm humbled that you would teach us your techniques. Having only made simple boffer swords, I had no clue how you would go about armor!

[@gamiensrule]

Ted, I've gotta say man thank you so much for keeping your videos clear, concise, and to the point. Nothing gets under my skin faster when watching a "tutorial" video when the author goes on and on about where they purchased a certain tool, or exactly why that tool was fashioned the way it was, or what happened to them the day before that made them decide to do a tutorial. Most videos I have to skip over vast portions of the junk just to get to the actual material, and if they cut out all the useless garbage the video would be like 30 seconds long. LOL. We love to hear you talk - I'm just glad you don't love to hear YOURSELF talk. Thanks for keeping it on subject.

[@EvilTedSmith]

gamiensrule Thank you, for your support. I do my best to focus on the subject at hand.

[@vickysweets2697]

This is literally the best tutorial a girl could ask for!!! Can't wait for part 3!

[@EvilTedSmith]

VickySweets Soon!

[@badgersbunk7311]

Keep em coming evil Ted. Your new videos are always the ones I watch first in my subscriptions.

[@realgdman4u1]

I am amazed at how fast you produced the Part 2 & 3 video! I shouldn't be, because after viewing some of your other work, it is obvious that you know what you are doing! I have to say that it is truly fantastic that you choose to share this knowledge with those among us who are interested in the craft! Just wanted to say thank you and you have inspired me to try my first foam armor! Hopefully I will mold it into a harder medium (if it turns out good!) Thanks again!

[@nehuenmorbidoni132]

I've been looking for videos to learn how to shape the foam into whatever i want and now I bumped into your videos which let me tell you are excelent, well explained and you take your time with the details. Great work man greetings from Argentina!

[@EvilTedSmith]

Thank you for watching and subscribing.

[@garylawson464]

ted.. thank you for all your hard work on these.... you have been my benchmark on foam works......love your work i will be doing this .

[@ModERnS0CiAliSt]

Evil Ted, you're the Bob Ross of prop & cosplay construction. Thank you for the detailed information, examples, techniques and sharing. Looking forward to whatever you're doing next. "_Any time ya learn, ya gain_." *_Bob Ross_*

[@LEE-kq9tq]

+Matt R YES, I had that same thought while watching this lol. Like it should be a show on PBS :P

[@mynameskilla]

I just can't get my head around how awesome this turned out. Your process looks effortless. I hope to do my own suit one day. Thanks so much for the awesome tips and showing us how you did this!

[@EvilTedSmith]

***** You'er welcome, and thank you for subscribing.

[@LEE-kq9tq]

I'm just totally addicted to your videos. Would love to see how you did the arm/glove armor that you show at the beginning of your videos.

[@EvilTedSmith]

+Lisa S One day I'll get to everything.

[@NightHawkX321]

Always got trouble using the thinner diamond mats and trying to put on a bevel. Glad you helped

[@chrismcelveen2839]

Your videos are so amazingly helpful! The amount of detail you show in these how-to and DIY videos...thank you so much.

[@EvilTedSmith]

James McElveen You're welcome, and keep watching!

[@winterephiphany]

I can't get enough of these videos. Maybe sometime soon I'll try my hand to make something small, like a helmet before I try to tackle a full set. This looks amazing and I look forward to more!

[@gavinmac1775]

Hi Ted, thanks for the best tutorials I've watched, I have wanted to make some steampunk armour for ages but lacked the knowledge. Have trawled through loads of tutorials but lost interest /the will to live hearing who, why, where, when, and what they had for breakfast etc. Love your clear concise and to the point tutorials. Can't wait to get started !

[@EvilTedSmith]

Gavin Macpherson Thank you so much for your kind words, and thank you for subscribing. I know you can do it. Good luck.

[@Ryuki19n]

I really want to attempt this after watching. Only problem is I don't cosplay or anything like that so it's going to be an expensive hobby. I had something in mind for years but never known the actual skills/techniques to even try until watching KZbin videos especially yours. They're very informative, thank you.

[@EvilTedSmith]

Ryuki19n Thank you, and it's not really expensive. Foam is one of the cheapest mediums you can use to build cosplay.

[@Hikaru119]

Soooo glad I found this before I started working on my own project. Hopefully your painting video is out before I get that far. Always look forward to these vids.

[@EvilTedSmith]

Ruke Ladamee Thank you Ruke

[@sticbits2839]

I'm probably going to use this for a Keith kogane or Takashi Shirogane from Voltron. I don't know yet, I just went to a con and I didn't see any armor shiros. So I'm going to work on this for a while

[@thespacebat]

The biggest thing I was having trouble figuring out was how I was going to do shoulder pieces, thanks!

[@EvilTedSmith]

You're welcome and thanks for subscribing.

[@gilberteaz]

Ted, You have the best complete video on working with foam. After watching your videos I have no question on how you did something. I have watched other foam videos that are not complete. Thanks you for making this videos. PS. You forgot the links to find the rubber tubing?

[@DeadTom22]

You are my hero Ted, your tutorials are detailed, well put together and you don't skimp out on steps. Looking forward to part 3. Sorry for the repeat, commented on the wrong video :P

[@nigeldonaldson1647]

I like your costume making videos, ive learned much from them all very professional

[@EvilTedSmith]

Glad you like them!

[@khaimapostol962]

Thank you so much for the tutorial! It's helping me a lot for my Thor cosplay.

[@hickdawg4147]

This is pretty awesome ! I'm about to begin my construction on Deathstroke's armor !

[@ArkhamKane]

Me too. I just wish I didn't have to use Plastidip... No place to spray it here... :(

[@Mememan1992]

WOOO PART 2, these are the best videos on cosplay building, the best man!!

[@itsyairo3149]

Thank you very much for these tutorials, they help me and my cousins out a lot with our cosplay's please make more!!!

[@LaVieEsthetique]

I'm so excited to start my first set of armor. Thank you for posting these videos!

[@shamitbarman8545]

that was really helpful, thanks. and do u hav any tutorials where LEDs r used in an armour? or better if you could do a tutorial on making Genos cosplay :3

[@allenfox7186]

I am planning on doing a N7 armor from mass effect in the future and this is really informative and can't wait to get my funds together and make this a reality.

[@EvilTedSmith]

Great news. You should get Bills E-book on Foamsmithing. eviltedsmith.com/product/foamsmith-create-foam-armor-costumes-e-book/

[@allenfox7186]

Evil Ted Smith Sweet! Thanks

[@jamminjelly117]

You fixed your audio issue, great! And great video!

[@purplepineapple7893]

Hurry witg 3rd vidddd . Lol this couldn't have come at a better time. I'm helping my brother do an outfit that requires this

[@bass-dc9175]

Tipp: if you do not have Kwik Seal: Use normal glue and babypoder. Mix it and you will get a gooi substance, which when dry, you can file down.

[@EvilTedSmith]

Great ideal.

[@oldguy4495]

Hey Evil Ted,Can you show a "how to" for Geralt of Rivia from Witcher 3 armor suit?

[@jacobh707]

Great stuff, thanks for the tutorial Evil Ted. Your helping get inspired for my next project, and that's the most important step!

[@aaninja2479]

This is vary helpful and now I’m not so scared of trying to make Blackwatch Mccree chest plate

[@EvilTedSmith]

I'm happy that I've helped.

[@dravenpool]

Your videos are really helping me out with my latest proyect, thanks!

[@EvilTedSmith]

Dravenpool Thank you for subscribing.

[@mcopado]

I've watched nearly all your excellent videos over the last few days, and unless I've missed it or yet to see it, but is seems that each time you heat form/bend a piece you do it off camera. Would you consider doing a video just on heat forming/ shaping pieces? I'm having trouble getting my head around how you get such good shapes, especially on shoulder pieces where it seems crucial that both halves bend perfectly to match. Thanks for everything you've done.

[@EvilTedSmith]

+Michael I do a lot of heat shaping in my helmet video. Check it out.

[@popplerchefs]

Thanks so much Ted, such a fantastic video and page!! Are the patterns for this armor available for purchase!?

[@EvilTedSmith]

Sorry, these are not...

[@popplerchefs]

Evil Ted Smith no worries at all! Thanks for the fantastic video all the same!!!

[@antcas9184]

Ted you are the man!! This is a great video and your others as well. So much information and all of this is going to push my prop making skills up!! Thanks so much and keep the videos coming!!

[@kylemcmurray806]

How would you do shoulders that overlap some of the torso like maximillian plate armor or German gothic plate armor.?The main reason why I ask the question is because of the how the connection would work out? Is there different types of of ways to connect the shoulders to the armor, like different setups?

[@EvilTedSmith]

You should get Bills book. eviltedsmith.com/downloads/foamsmith-create-foam-armor-costumes-ebook/

[@LetsMakeCoolStuff]

Thank you Ted I am learning so much from this build. Can't wait for the next one mate.

[@jonthemachine1970]

Hey Ted Love your stuff I have built almost all the foam projects on your site and they look great. The paint jobs...not so good, but i will get better. Looking forward to more cool foam projects from the master! Maybe a foam shield or perhaps even a full set of armor. Either a mid evil armor or a Modern style sci-fi armor. Just sayin. I would be all over it. I need more practice. Lol Thanks Evil Ted

[@Krazy_Kenny]

How come your EVA foam looks so clean cut and smooth? Mine was a mess around the edges where I cut it, and also the surface was porous. Also, how can you heat-seal your foam without losing its shape? I applied heat to my curved pieced and it quickly started to open up again. Thank you.

[@EvilTedSmith]

***** I have my supply list just below my video.

[@juggalizzle75]

I've got a hell of a armor set for you. Plus I could follow the tutorial since it's above my head ;) it's a starwars character named darth revan. It has engraved and embossed areas as well as straps and metal rings you could demo how to do. Anyway it's a thought. Subbed

[@Kouin]

I would really love to see something like this but for female armor, like a full female chest piece that covers up to the neck. How to pattern it and get the curves is something I'm struggling with for a character like Lady Thor.

[@EvilTedSmith]

Ari Trembley OK, check out my How to Make Female Foam armor video.

[@rafaelcetraro1475]

Thank you Ted for these wonderful videos, love them!

[@EvilTedSmith]

Rafael Cetraro No, thank you!

[@indigo8lue]

Is there a cheaper alternative to creating professional looking holes in the foam aside from using a dremel?

[@EvilTedSmith]

demomen Yes, check out my tools of the trade video.

[@gamiensrule]

demomen i just recently purchased a dremel at a pawn shop for $8 dollars. It's the lowest of the low models, but it does the trick, and it's SO FREAKING HANDY. You can get the entry level model for about $25 new. Not sure if it's powerful enough for this, but I was able to cut ports in my Chainsaw Muffler with it (grinding metal with a caribide tip). $8 DOLLARS USED! Can't beat that price.

[@anakinmonkey]

demomen I was wondering the dame ting, I was thinking of pressing a cap into it

[@kevinwang1668]

what is different between using plastic dip then paint and using supper 77 、balloon rubber then pain?

[@EvilTedSmith]

Kevin Wang It's just a preference. Whatever works for you is fine.

[@jeromemcfarlen9415]

Thank you for the great tutorial. You are an amazing artist sir.

[@EvilTedSmith]

Jerome McFarlen Thank you for your support and for watching.

[@ShinAioros]

Mr Ted i'm thaks for another Great Video tutorial !!!! I'm a big fan of you're works . I hwait the part 3 of this tutorial ^////^ . Thank yuo so mutch !

[@EvilTedSmith]

Thank you for watching.

[@JabbaBATMAN19]

do you have like a drawn out template by any chance??

[@pchpchpch]

For your details, say the hexagon pieces, did you use super glue or contact cement?

[@EvilTedSmith]

I use contact cement.

[@billycustomfab]

Great Video, I really enjoyed your style of teaching along with all the tips! Thanks a lot for making this video and yep, I subscribed and will be checking out more of your videos. Thanks for listing where to purchase tools and material. I also went to your website. Thanks again.

[@princess535353]

This seems like the most detailed way to make armor! But I'm on a budget and don't have all the tools for this. But the heat gun seems really important. This might be a really stupid question but would a hair dryer work?

[@EvilTedSmith]

Sarah Ellsworth On thin craft foam but not EVA.

[@scottschofield5000]

Ian Le Gallo-Malone check out Harbor Freight too, if you have them in your area, they are almost always on sale. I got one for under 10 bucks during a labor day sale last year.

[@Anzho]

Great video, thanks for posting it! I was wondering if you encountered any wrinkles after painting. I heard this happens over time?

[@EvilTedSmith]

Anzh Castillo Yes, that's why I try to use acrylic paints, because they are flexible.

[@GuardianLords]

How long did it take to make excluding paint time?

[@CraftyLadyLinda]

I make wings, mostly faerie wings, dragonfly wings, etc... I have wanted to make bat wings and bird wings too. I know that those both need to be able to fold, so I'm thinking of making bat and bird "inspired" wings that are stationary. I'm pretty sure I can figure out how to do the bird wings. Can you recommend something that might work for the bat wings?

[@RoboRizzlerDrip]

If you make foam body armor or a helmet and then coat it with Plasti-dip, would it be strong enough to make a mother mold of the piece with silicone and fiberglass?

[@MisterDeth0]

I am curious of this as well.

[@kristydemon]

I would think so, most people model out of soft clay then make a mould, so I'd say that would be strong enough

[@dan36100]

c'est super se que vous faite , mais c'est quoi comme mousse ?????

[@paologiuffrida6983]

Great work Ted!!!

[@EvilTedSmith]

Paolo Giuffrida Thank you.

[@marinalinderman9000]

Thank you! What a helpful tutorial! You make it look so easy. Where do you go for inspiration when designing your own armor?

[@TheHooty505]

hey Ted awesome videos thank you for posting them they are super educational, quick question though is there a specific type of foam rubber tubing/rod that you prefer working with? the website you listed had several types.

[@EvilTedSmith]

What ever size works for you. As long as it's flexible.

[@TheHooty505]

ok just didn't know if neoprene or the other types of rubber tubing took paint differently

[@justinharrison9839]

Can you do a video on making a RoboCop costume

[@theistrix8675]

once that contact cement dries and sets do you think it can hold weight? Like i was thinking about attaching shoulder pieces to a jacket, and then attaching a small chest part by fabric strap to give mobility and leave the chest just hanging. Think those seams will hold up?

[@EvilTedSmith]

Yes, they will hold up.

[@hiba]

This is great! I really like the dull effect after the plasti dip is sprayed.. could you tell me if "car undercoating rubberized spray" will work like plasti dip or not? couldn't find plasti dip anywhere near but found the undercoating rubberized spray..

[@EvilTedSmith]

It will work but dry a stiffer then plastidip.

[@hiba]

oh okay i'll try then.. Thanks for your response..

[@vendettanovember05]

Evil Ted Smith im in the painting process with acrylic airbrush. What would i use for a finish? Like a sealent?

[@EvilTedSmith]

leonardo ocampo Future Floor wax amzn.to/1mgo3aD

[@vendettanovember05]

Thank you lots! You insipre me to cosplay

[@LovesHina]

Evil Ted Smith I recently used some Future on a project, and had a bit of a problem with running since it's thinner than what I'm used to spraying. Is there any way to thicken it? Also, thanks for the awesome vids.

[@EvilTedSmith]

The trick is to very thin layers. You can't go to heavy or yes, it will drip. Spray super thin and let dry before adding more coats.

[@LovesHina]

Thanks, I'll give that a shot. Does it need to fully dry between coats, or just set up?

[@ericstaples7220]

I understand how many cans you used, which is useful for letting me know how many to buy, but exactly how many coats did you do? I'm assuming 3 is good.

[@EvilTedSmith]

Yes 3 is good.

[@Marius2Rocker]

Would you discourage this level of complexity in a cosplay from complete beginners to the cosplay/armor crafting thing? I'm thinking something like a Dark Eldar Archon, and wondering if it's abit overambitious for a "first"...

[@EvilTedSmith]

+Marius2Rocker Start with something you really want to build and take it from there.

[@albertorodriguez3385]

Great job!! i have one cuestion. which is the thickness of this foam and which is it his density? Thanks and good video.

[@EvilTedSmith]

My supply list is just below the videos.

[@andrewb9590]

Awesome tutorial. Thanks for posting. Do you have links for Canadian Amazon as well? Can't order from amazon.com in the Great White North...

[@FutureLaugh]

i dont see the duplicolor perfect match gun metal spray in the amazon list

[@tomrabel3526]

Love your Channel! One question, how would you do the tubing that you'd see in a futuristic detail. For example, hoses that have the ribbing or seams such to simulate a flexible metal hose? Do they make EVA tubes to score and heat so the lines are visible?

[@EvilTedSmith]

I just but flex hose for that.

[@charliefreilich5885]

Can you send me the upper chest templates? (If you have them). Thanks!

[@PunkkPanda55]

I would also love those

[@carrots7216]

Looking at this for Raiden from Metal Gear Solid is really helpful. :3 Thanks~

[@kylenguyen7371]

+Pocky Games You going for the Skull Suit from MGS2 or his MGS4/Rising appearance? Either way, he's a pretty slick choice.

[@carrots7216]

Probably his Rising; though it's a pretty long-term project, I hope I can get this done, haha. And thanks!

[@thealphawildcat5868]

Do I have to use Barge cement, or can I use another form of glue, like wood glue?

[@EvilTedSmith]

Check out my Tools Of the Trade 2.0 video.

[@thealphawildcat5868]

OK. Thanks.

[@thealphawildcat5868]

Is the white piece on your armor 3D printed?

[@EvilTedSmith]

No it is not.

[@llollercoaster]

this looks pretty awesome.. how much do the materials usually cost for a set of armor?

[@EvilTedSmith]

+llollercoaster It varies foam the type of foam you are using. I was used floor mat foam, so about 20 bucks.

[@rileycaton1502]

+Evil Ted Smith that is not that much

[@meepymoof]

Do you heat seal the pieces as you go, or at the end right before you spray your plastic coat? I figured the latter would warp the finished pieces and ruin the design, but having never worked with eva foam before I wasn't sure.

[@EvilTedSmith]

I heat seal it when I'm done building before I seal it.

[@meepymoof]

Thank you so much for responding.

[@BalliSutera]

I love these videos. Thanks so much for making them. They're a huge help. :)

[@EvilTedSmith]

BC Rice Thank you for watching and subscribing.

[@timothymcdaniel7372]

Awesome set of videos! How did you do such a nice bevel for the armor mid and lower armor pieces? I'm working on some armor for a friend and the front of it has overlapping pieces like this.

[@wildandwillfulvids]

When you pin the foam- do the holes that are made expand when you heat it? I know that some people use cuts and a heat gun for detailing, and these little cuts show up really well once it's heated. I don't want to mess my armor if I use pins on it then heat it.

[@EvilTedSmith]

VeraVideos Yes, but there so small that they get filled in when you seal it.

[@MelanieOregon]

Hi again. Thanks for the videos & info. Ok a few more questions: How did you "temporarily" attach the hanging tabs & how did you remove them w/out ruining your armor (without me watching other vids please & I'm wondering if you cover removal of tabs in next segment but I haven't seen it yet so asking now). Since Barge cement is toxic I know you're supposed to be wearing gloves & a respirator. I see you don't use them in your tutorials usually. Do the gloves make it pretty difficult to work w/ the barge cement &/or any other adhesives (like do they stick to the gloves)? Forgot my other question after reading 252 comments to see if it was already covered... sigh... will try to remember it later.

[@EvilTedSmith]

As for the tabs. I cut them out. When working with barge cement. I have a fan blowing toward just off camera. If your working in a small room, then you should wear a mask, plus open a window.

[@MrPaulmcalpine]

Hi Ted. I would like to make armour inspired by your work for both cosplay and also for light sabre duelling. how well would it hold up to heavy combat? I am not worried about the foam itself but more for the joints giving way.

[@Ryu62Alpha]

I'm curious, what is the brown paper you use to cut out the templates with? It seems really resilient!

[@EvilTedSmith]

+Minh P Just heavy brown wrapping paper.

[@coldboy0912]

What is the difference between plastic dip spray u used and the normal spray paint? Thanks

[@EvilTedSmith]

+Randy Orton Plastic dip is a flexible coating I use the seal the foam before painting. Spray paint is just paint.

[@coldboy0912]

woa, thank you :)

[@Mr0Smith1]

Ted, I noticed that after painting you still had some seams showing. Do you do any extra work to fill those in? Or do you just leave them be?

[@presidentliam8610]

Hey +evil ted! Don't mind my name but... I have a question. What kind of paint and primer did you use on the armor. I was really curious as I am currently making armor myself! Thanks! You video was very helpful by the way! 10/10!👍🏽

[@LuisJoestar]

Your videos are so useful and amazing as well Ted,it gave me a lot of ideas on how to work with a foam armor that I plan to make in a couple of days,but I have a little question. How many days took you to finish this armor? Thank you so much for making this videos

[@EvilTedSmith]

Luis Joestar About 4 days… When making a costume, take your time to do it right. There is no benefit to rushing to get it done. It's your costume. Take as much time as needed.

[@Pozotronree]

Am using 6mm foam to build some Daedric Armour is that a OK thickness? or would you say it needs to be thicker

[@EvilTedSmith]

+Rastafarian 6mm will work as well.

[@Zulfburht]

could you do some boots?

[@allenwheeler1713]

Evil Ted are there opportunities out there for creative individuals to get more education to be able to do this for movie's or prop creation teams?

[@EvilTedSmith]

My advise is to keep building and make a portfolio of your work.

[@zorbagg1]

huh...never seen anybody sharpen a stanley blade with a knife sharpener... I oughta try that sometime...

[@schi2989]

With your skill i think you would be able to make a Genji cosplay from overwatch. It would be awesome! :D

[@Spencer-mn5lm]

i was thinking reinhardt

[@aidencarruthers961]

I was planning on doing Genji. I just don't know how.

[@Hyperguyver2]

This looks great so far!

[@manjo49]

is there an alternative besides 3M spray 90 and barge cement?

[@EvilTedSmith]

+Hazmi Fadzil Yes, check out my tools of the trade video.

[@119wolverine]

been looking for channel like this. awesome

[@EvilTedSmith]

+Kama Shafik Glad to be of help.

[@KamiEntertainment]

What kind of specific material is it? I know its foam, but never knew you could form it like this.

[@randomgamerz360]

+KåMi CyrosBlaze EVA foam.

[@EvilTedSmith]

+KåMi CyrosBlaze I have my supply list just below my video.

[@cogwheelfeline7666]

Did you make the mannequin you use in this? :0 if you did, how? Because I'm kind of tempted to make a plaster mannequin and coat it with something to keep it from chipping because I can't find anything with my bodyshape and my ducktape ones are flops :/

[@EvilTedSmith]

I have links for body forms below my videos.