GEN2 Scout/Palmer 2.0 build - EVA foam

Reclaimara

Well-Known Member
Member DIN
S713
Doing those plates for the fingertips. Gotta admit they make me question my sanity a little. Especially when I think I'll have to do all those pieces I'm doing again for the second hand.
I like how they are coming together - they look nice and round on the fingers and are comfy but as you can see on the left - they consist of a lot of tiny pieces to make them.
At first I tried making it out of 5mm foam (on the left on the photo) but it turned out very bulky due to thickness of the foam and I'd have to shave of a lot of foam to make them look nice (and to make them comfortable). So I'm making those fingertips out of 2mm foam and works great - they'll look more sleek when I glue them to the glove from the sides.

My old pepakura fingertip for comparison - gotta admit those foam fingertips are much more comfortable to wear on the fingers and you still have some kind of feel through them while resin pepakura made your fingertips completely numb (due to hard resin over your finger) when you were touching or holding anything in the hand.

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Reclaimara

Well-Known Member
Member DIN
S713
So. I did that big plate but I'll have to redo it. I don't really like how it turned out (I forgot a detail that I tried to do after I finished it but I don't like how it looks like) so I'll be redoing it. No issue as now I know how to do these.
At least now I see how the whole glove will look like.

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Reclaimara

Well-Known Member
Member DIN
S713
Ok. Hand plate finished. Looks much better now than the first one I did. Both foam parts are same size, just on the photo the perspective makes the failed one look smaller. Also they both are little smaller than my old pepakura.
Whole right hand finished and just gotta do all parts for the left hand.
Tomorrow I'll also start plastidipping and spraypainting the parts I have finished cuz I want to see the progress I've done.

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Reclaimara

Well-Known Member
Member DIN
S713
Another small setback. Earlier I looked on the internet and according to some people Montana Gold supposedly doesn't crack easily on foam so after my first Palmer costume where I used those paints and loved the colors and texture I bought it again and planned to use it on this one again.
Luckily I didn't order few cans of each and also luckily I did a test piece.
Unfortunately Montana Gold still cracks so I don't recommend it if you care about cracks.
From what I tested - thin coat cracks immediately. This on the picture is 3 thicker layers of spray paint which makes it bit more durable but as you can see - it still cracks. It cracked under less pressure than on the photo - I just bent it more to show the cracks better.
So I suppose if you want to make a quite hard and sturdy prop/armor Montana Gold will work amazing but on foam that it's gonna be bit more flexible you'll have to expect some cracks.
No point in painting some harder armor pieces with Montana and other parts of armor with other paint as it'll be hard to match the exact colors.
I don't want to spend months foambuilding only then to have it all crack on me and ruin all my work.

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I've ordered something else - Flexi Paint which according to many cosplayers and videos I've watched - is very flexible and doesn't crack.
It comes in just few basic colors but you can mix it and you can even thin it out and spray with an airbrush.
I have an airbrush so this is what I precisely plan to do with it although I'll test both options.
As a bonus Flexi Paint is non-toxic so I'll be able to paint it indoor with no problems (I don't have a workshop or dedicated workspace outdoor, basement, garage, etc.).
Maybe I should have gone with Flexi Paint from the beginning but I was hoping Montana would work and it'd spare me the work of mixing colors and airbrushing as can spray paint covers faster. But with having airbrush now I'm planning on doing better paintjob on the costume anyway than on first one few years ago.
I hope it'll arrive this week but in the meantime I'll finish plastidipping the pieces I have and do the foam parts for the left glove.

 

Reclaimara

Well-Known Member
Member DIN
S713
Almost finished making all the armor parts for the second glove. Only 3 fingertips left and done. Gotta admit really happy how these came out.
In the meantime I've finished plastidipping all the parts I have so far - it's amazing how they change the appearance.

On some parts in few places I've dremeled out some tiny dents, they might not even be visible but just some small details that the armor isn't brand new.
I only need to get distilled water and then I'll do some paint tests and hopefully paint them. I'm planning to try the paint chipping method and how it'll look.

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S229

Member
What thickness of foam are you using? Just from looking at it, it looks thinner than 2mm which is the thinnest i've been able to find.
 

Reclaimara

Well-Known Member
Member DIN
S713
What thickness of foam are you using? Just from looking at it, it looks thinner than 2mm which is the thinnest i've been able to find.

Combination of 5mm and 2mm foam. The fingertips are done with 2mm foam (at first I tried making them out of 5mm foam and it was a fail - foam is too thick for that). All other parts for the glove are either 5mm or combination of 5mm with a 2mm layer for details glued on top.
 

Reclaimara

Well-Known Member
Member DIN
S713
Finished all parts for gloves, plastidipping all the foam pieces I have so far.
And now I've started to airbrush the gunmetal Flexi-Paint. Gotta admit I'm honestly shocked how it comes out. That paint in the bottle looks like generic gray color (can see on the pieces on the left that are still most wet) but when it dries suddenly magic happens and it really becomes metallic (top right piece is most dry). Call me bamboozled by this space magic.
Also this paint is so flexible! I didn't wear glove on the hand I was holding and after airbrushing when I was peeling it it felt like a thin layer of plastidip/latex. 10/10 from this very early experience.

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Reclaimara

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Member DIN
S713
One does not simply do a test piece.
As a test I did one of the small ankle parts. Turned out nice and I really like the results so I'll be continuing with the same process.
This is pretty much what I plan to do for the paintjob on the whole costume. Just later on I'll do some washes to make it appear more dirty and dusty. And buff some parts where the metal is showing through but I like how dark this gunmetal is - darker than silver so white/light gray isn't blending together with it. There is quite much contrast that I wanted to have.
I really like how these are turning out but damn it's taking a long time - from up close you can physically feel and see the white paint being separate and having this chipped effect. Airbrushing is much slower than spray pain but I enjoy the process.

On the photo it might seem excessive but those are tiny pieces and from 1m it looks just like details.

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Reclaimara

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Member DIN
S713
More progress on painting.
The big front piece on the left is just plastidipped, the smaller middle section piece is airbrushed with gunmetal flexi-paint. Almost same shade just it has that nice metallic gunmetal. And McFarlane Palmer for scale.
Slowly starting to coat all the pieces with gunmetal so far. I know I didn't have to start painting process now when I only have a tiny % of the armor done but to me it was test if I can make this whole armor out of EVA foam and be satisfied with it. And paintjob can cover up a lot of imperfections of the foam (seams, etc.) too. So now seeing how it's turning out I got a confidence boost because I'm happy with how these are turning out.
As I really enjoy the painting process I may as well do some more pieces but I'm slowly moving forward onto the building the shins soon too.

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How those ankle pieces will look like on the shoe.
I won't make whole armor overly damaged. Some areas more and some other areas less. Depending on the use and where you could bump into and it would cause damage to it. I think the boots would take a lot of damage due to always being in more direct contact.

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Reclaimara

Well-Known Member
Member DIN
S713
More on painting. It's much more time consuming but I really like how all these are turning out.
Big improvement compared to the old gloves (only fingertips to finish for first glove). Really glad I decided to redo them.
When looking at these pieces in the mirror from approx. 1m away those are just nice details and aren't overpowering as too immense damage. Which is what I intended.

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