Some Questions About EVA Foam Armor Building

Infausto20

New Member
Hello Everyone!

I just got into this community and am looking to create a suit of halo armor because I think it would be a really cool project that I could work on in my off time. I have a helmet that I'm having a buddy 3d print for me but otherwise I want to make the armor out of EVA foam. I was looking through the armory and decided that I wanted to make a Mark V armor set (because I really loved the Reach game and because my helmet is the Scout/Jun Helmet). So, naturally, I downloaded Pepakura and the files in the armory for foam. I then loaded up the files just to take a look at everything (not planning on starting anything yet) and realized that I had no idea where to begin. I looked up a couple tutorials that gave me a rough sense of how to do some stuff but none of it was as helpful in terms of what I should do for my build. There were concepts like beveling and making lips for other parts to sit on, and I was a little familiar, but didn't know where to put my own or utilize them, and realized that it seemed a little complicated. I was wondering if anybody had any tips or helpful videos making any of this stuff that I could use as resources. I would love to make some detailed armor and I don't want this to be a roadblock. Thanks for anyone's time that views and responds to this!
 
Hello Everyone!

I just got into this community and am looking to create a suit of halo armor because I think it would be a really cool project that I could work on in my off time. I have a helmet that I'm having a buddy 3d print for me but otherwise I want to make the armor out of EVA foam. I was looking through the armory and decided that I wanted to make a Mark V armor set (because I really loved the Reach game and because my helmet is the Scout/Jun Helmet). So, naturally, I downloaded Pepakura and the files in the armory for foam. I then loaded up the files just to take a look at everything (not planning on starting anything yet) and realized that I had no idea where to begin. I looked up a couple tutorials that gave me a rough sense of how to do some stuff but none of it was as helpful in terms of what I should do for my build. There were concepts like beveling and making lips for other parts to sit on, and I was a little familiar, but didn't know where to put my own or utilize them, and realized that it seemed a little complicated. I was wondering if anybody had any tips or helpful videos making any of this stuff that I could use as resources. I would love to make some detailed armor and I don't want this to be a roadblock. Thanks for anyone's time that views and responds to this!
usually most people starting with foam start with a foundational build. something easier with less details like an ODST or Marine. These help you learn how foam works and how different angle's and cuts can affect your build quality. I did this to a small extent. I built literally 3 foam armor pieces before starting my spartan and that was a mk V(B) commando shoulder and an odst chestplate and shoulder. then i started my spartan... I would say to learn these concepts try building something maybe try building a piece of armor and seeing if you are happy with it. if not rebuild it! i rebuilt my shins about 3-4 times before i settled on some I liked! failure is a part of foamsmithing and honestly that failure allows you to learn more! so try some angled cuts and put it together to figure out how it works! or try building some armor and if you arent happy with it then rebuild it! I hope that helps a bit!
 
realized that I had no idea where to begin. I looked up a couple tutorials that gave me a rough sense of how to do some stuff but none of it was as helpful in terms of what I should do for my build. There were concepts like beveling and making lips for other parts to sit on, and I was a little familiar, but didn't know where to put my own or utilize them, and realized that it seemed a little complicated. I was wondering if anybody had any tips or helpful videos making any of this stuff that I could use as resources. I would love to make some detailed armor and I don't want this to be a roadblock. Thanks for anyone's time that views and responds to this!
Hi Infausto20
I know this is a very late reply, but I haven't been online lately and I wanted to go through all of my unread treads. If you're a complete beginner and you're looking for a one-stop shop that covers the overall process of making halo armour out of foam, I'd like to share with you my video tutorial:

Hopefully this video will give you a good idea of the overall workflow of working with foam and making armour in general. If you have any specific questions please do not hesitate to ask! If you would like more guidance let s know as well.

There are many written foam tutorials on the 405th, but they tend to only be helpful for specific foam armour pieces. The only broad tutorial that i'd recommend reading is this one:
 
Hello Everyone!

I just got into this community and am looking to create a suit of halo armor because I think it would be a really cool project that I could work on in my off time. I have a helmet that I'm having a buddy 3d print for me but otherwise I want to make the armor out of EVA foam. I was looking through the armory and decided that I wanted to make a Mark V armor set (because I really loved the Reach game and because my helmet is the Scout/Jun Helmet). So, naturally, I downloaded Pepakura and the files in the armory for foam. I then loaded up the files just to take a look at everything (not planning on starting anything yet) and realized that I had no idea where to begin. I looked up a couple tutorials that gave me a rough sense of how to do some stuff but none of it was as helpful in terms of what I should do for my build. There were concepts like beveling and making lips for other parts to sit on, and I was a little familiar, but didn't know where to put my own or utilize them, and realized that it seemed a little complicated. I was wondering if anybody had any tips or helpful videos making any of this stuff that I could use as resources. I would love to make some detailed armor and I don't want this to be a roadblock. Thanks for anyone's time that views and responds to this!
Hey! It's so exciting that you are thinking about making a foam armor set. I for sure felt the same way when I was making my first suit out of foam. I also use Pepakura to get my templates. I recommend you look at the Pepakura templates and try to join edges to make more manageable pieces. Pep often has so many tiny pieces and sometimes they are not necessary. Pepakura templates will also have so many tiny details that you can often leave off and add later with smaller pieces foam. One other tip I have is to scale the piece in Pepakura first and then print it out to test it against your body. I usually print out a few pieces of the template that I can easily check the size with and that are major parts of the armor piece. One more tip is to cut out the Pepakura templates and roughly tape them together before transferring it to foam so you can get an idea of how the piece will need to be shaped and what seams need what kind of beveling. Good luck on the build and know there are many resources to find if you get stuck!
 

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