Best option for a smooth finish on Foam?

[discjohn117]

So im very new to COSPLAY and decided to do an ODST get-up. Learned its a great destressor but im struggling on how to best smooth out the foam in the most efficient and or best way possible.... any pointers? caulk, e6000, foam clay, epoxy and sanding?

 

[Beemo8bit]

First thing is make the cleanest cuts possible, and make sure any dremel sanding you do is slow, smooth and careful. Then use a heat gun to close the small cells of the foam up, or else it soaks up the paint. Then it’s typical to give it a flexible undercoat with plasti dip spray. There are a few good YouTube videos on using the spray to vest effect.

 

[discjohn117]

First thing is make the cleanest cuts possible, and make sure any dremel sanding you do is slow, smooth and careful. Then use a heat gun to close the small cells of the foam up, or else it soaks up the paint. Then it’s typical to give it a flexible undercoat with plasti dip spray. There are a few good YouTube videos on using the spray to vest effect.

Appreciate it

 

[DeltaAlphaZulu]

For cleaning up seams kwikseal caulking and a small amount of water works good. I've also used caulking tools to tidy up cracks and crevices to get smooth transitions between multiple layers on joints and seams too. Also for a base coat that resists cracking and has really good flex to it I used Valspar Duramax Exterior house paint. It seals the EVA well and is a good primer for whatever else you want to put on it. It's more expensive initially than plastidip, but if you're going to be doing a lot of cosplaying a gallon can could probably do like 5 suits if not more.

 

[Deltaraven]

I have used Primer/Sealer spay paint, seems to fill in the small gaps and bends.

Robot or human?

Krylon is my favorite. Also Pasti Dip has helped.

Robot or human?