1st Build [FOAM] MKVb Noble 6 Helmet

[Redzxv]

Hi, I'm Redzxv from the Netherlands!
Beforehand: English isn't my first language so excuse my spelling errors. lol

This is my first time posting a thread and working with foam, I had no prior knowledge of working with EVA foam.
But I wanted to try since it looked fun! I enjoy crafting things even though I'm not really good at it. Practice makes perfect right?

For now I'm focused on getting better at working with EVA foam, cutting techniques and gluing (because my seams are a mess lmaoo)
If you have any advice on how to improve on those things, or well, any other things, feel free to leave a comment.

I'm using zealotops unfolds for the pattern.
Right now I'm just building the helmet with 6mm foam, In the future I might attempt a full suit build. But for that I need to be more confident in my foam work.
I'm considering this a test run and a HUGE learning experience before attempting another build. So i'm fine with the imperfections.

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LAST WEEK: First I needed to transfer the pattern onto the foam. I saw some tips using pins to keep the paper in place with helped a ton!
It took me several hours to cut the patterns out and transferring them onto the foam.

LAST WEEK: The actual top part of the helmet was taking shape and I was actually proud of myself of even crafting a decent piece!
Some of the seams weren't lining up perfectly and I used too much of a bevel on some parts.

LAST WEEK: Glued the back piece and the top piece together. The indents on the top part of the helmet were a nightmare to construct.
There are a few gaps near the seams in some spots, figured I can later fill them up with some spot putty or foam clay.

TODAY: After the top part and the back I started on the jaw part. The vent(?) parts were really hard to construct with 6mm, so if I make another attempt in the future I might go for 4mm foam to get more detail in and an overall cleaner look. Still some gaps showing in some spots because of my messy cut lines.

TODAY: Glued the jaw piece and the rest of the helmet together and it's looking a bit wonky. That might be because I haven't finished the ear pieces to give it more stability. But it's actually starting to look like a helmet! So far it's definitely a case of "trust the process" lol Later today I'm finishing up the ear pieces If I feel like it.
I also got a rotary tool yesterday so I can start cleaning some edges up. So far I've already learned a lot while constructing!

That's all for today! I'll update once I finish the ear pieces.
If you have any advice/tips or whatever please share!

I'm looking to learn from this helmet build so I can make my next helmet even better.

 

[N8TEBB]

For now I'm focused on getting better at working with EVA foam, cutting techniques and gluing (because my seams are a mess lmaoo)
If you have any advice on how to improve on those things, or well, any other things, feel free to leave a comment.

There are two things I've found really help with messy EVA cuts and seams.

First, make sure your blade is SHARP. Get yourself a nice knife sharpener and make good use of it. Seriously, I'll sharpen my blade every 5-10 cuts. The foam should cut easily on the first pass. If you have to push down hard or worse, saw back and fourth, your blade is way too dull.

The second thing that helps is a rotary tool. I'll sometimes sand down my cuts before gluing the pieces together if it's critical they align nicely. I'll also sand the seam a bit after they're glued so there's no misalignment between foam pieces.

Right now I'm just building the helmet with 6mm foam, In the future I might attempt a full suit build. But for that I need to be more confident in my foam work.

With any build, the helmet is usually the most involved piece. So even if this helmet doesn't turn out absolutely perfect, don't be discouraged! Many folks (including myself) will build their whole suit out of foam, but 3D print the helmet because it's so hard to get right when made from foam. After you finish the helmet, try building other armour pieces. I think you'll be surprised just how much easier the rest of the armour is compared to the helmet.

lued the back piece and the top piece together. The indents on the top part of the helmet were a nightmare to construct.
There are a few gaps near the seams in some spots, figured I can later fill them up with some spot putty or foam clay.

Foam clay (sandable) or caulk (not sandable) will be your friend for filling gaps. Do not use spot putty. It's too rigid and will crumble and break away from your foam work. Personally, I use Kwik seal caulking to fill the small seams between my foam pieces. I've also heard some folks use flexible spackle, which is sandable.

After the top part and the back I started on the jaw part. The vent(?) parts were really hard to construct with 6mm, so if I make another attempt in the future I might go for 4mm foam to get more detail in and an overall cleaner look. Still some gaps showing in some spots because of my messy cut lines.

Sometimes instead of creating each part of small geometry with a separate piece of foam, those small details can be carved out of thicker foam. Just cutting with a sharp knife and sanding with a Dremel can create some surprisingly detailed pieces.

But it's actually starting to look like a helmet! So far it's definitely a case of "trust the process" lol Later today I'm finishing up the ear pieces If I feel like it.

If you are able, find a rigid visor for the helmet. It will help support the helmet and keep it symmetrical. Hopefully with that, and the rest of the foam pieces, it will even out the way you want.

I can see you've put a lot of work into this helmet already and I hope it turns out the way you're hoping! With a sharp knife, a Dremel, and some foam clay you should have a good looking helmet by the end of it.

 

[Zackurai]

Do love me some foam, quite brave to tackle a bucket with foam though