Mark VI high-def foam armor WIP

Gamemaster · Jan 10, 2011

Project stats thus far
Start date: Sat, Jan 8
Foam: 1 sheet (2'x2')
Formed: Helm, L. forearm
All pictures: http://s1087.photobucket.com/albums/j479/Puppyloveconnex/

First step was to print the patterns (without tabs) cut them out and join some of them prior to cutting the foam.
Cutting out the shapes took about 3 hours, I used a ruler and razor and some wood carving tools. I also scored the back with a wood burning tool, lightly for rounded and deeper for sharper corners (mountain folds only) and cut about 1/2 through the foam for valley folds. Also, I used sharp scissors to cut angles on any pieces that connect with others on a mountain seam.

Then I started to assemble, doing the large pieces first

It formed quite nicely, and you can score the inside to further form it as you go.

I did have to do some custom work around the front, and it still needs alot of work... but overall I am happy with the results.

OK, onto the torso, larger, but should be easier as there are less tiny pieces.

sonic sod · Jan 10, 2011

dats sexy i neva seen a foam helmet before good job

LongShot X · Jan 10, 2011

Does the helm fit?

Considering that it's foam.... Not bad!

Can't wait to see more!

Gamemaster · Jan 10, 2011

Oh yes, it fits, needs padding tho, otherwise you look like a bobble head.

LongShot X · Jan 10, 2011

mmmmm B O B B L E Head. LOL

I think I might have some spare padding around for that.

Dragon Sunkiller · Jan 10, 2011

Wow! Way to go! I'm going to do my armor in foam, but I thought it would be impossible to do the helmet, so I'm pepping it. I think I was wrong....

Gamemaster · Jan 11, 2011

The helm was difficult and still needs proper shaping and detailing to call it done. Since the last post I have designed the torso patterns and cutt them out

I also scored the back with the hotknife where I want detail on the front. I can always add more or deeper lines later to get the final definition, for now I want to get the basic shape together.

Then I began assembly

Its almost done, just need to make the top side parts and finish the detail pieces

rino626 · Jan 11, 2011

This is looking great gamemaster! Never thought of making a foam helmet! And the chest looks great! Keep up the awesome work!

spartanb312 · Jan 12, 2011

foam build good one

Gamemaster · Jan 12, 2011

Project stats thus far
Start date: Sat, Jan 8
Foam: 4 sheets (2'x2')
Formed: Helm, L. forearm, Torso
All pictures: http://s1087.photobucket.com/albums/...ppyloveconnex/

Here is a front and back of the work thus far, minus the shoulder vents.

I am learning alot of tricks to get the shape to form by cutting and scoring the backside. I think that a hotknife is essential for any detailed work. As for the helm if you look closely it is warped on the left side... the lower sides and front were very difficult, I am wondering if a foam back/top and pep'd side/front would work together? The back of the helm in foam was easy peasy.

Unity · Jan 12, 2011

That is awsome! Considering its foam! I have wondered about a foam helmet, and Now I know it works! Ill have to try it with a halo 2 odst! Thanks for posting this !

Jacob

sonic sod · Jan 13, 2011

what chest file is this could you please pm me a link

Gamemaster · Jan 13, 2011

I am not sure where the files are, Longshot brought them over on a thumbdrive and installed everything. I am using low-def files and then printing certain pieces in high-def and cutting/burning the detail work. Here are some pics so far.

IllynReaver · Jan 13, 2011

Makes me wish I'd started mine out of foam instead of pepping it lol! Looks good.

Gamemaster · Jan 18, 2011

Project stats thus far
Start date: Sat, Jan 8
Days off: 2
Foam: 5 sheets (2'x2')
Formed: Helm, L. forearm, Torso, R. forearm
All pictures: http://s1087.photobucket.com/albums/j479/Puppyloveconnex/

For the torso I tried some definition with a hotknife and wood burning iron, looks OK for foam.

Since those pics I've also added the missing shoulder parts
I did a right forearm next, to compare against my first piece. My skills have improved.

Next plan is to finish the arm parts and then the space ginch (aka space diaper, galactic speedo, moon thong, blackhole cover etc).
Legs we will do last.

LongShot X · Jan 19, 2011

I can definitly see that your skills are improving. The right forearm has less poligon edges to deal with and looks smoother.

Keep up the good work.

Cheers!

009 SPA · Jan 19, 2011

This looks seriously legitimate. Foam armouring looks like the new best way to make high quality costumes cheaply.

0235 · Jan 19, 2011

this is amazing,i cant believe that it is made out of foam. yet another foam armour maker that is showing to be very very good.

scout892 · Jan 19, 2011

looks amazing, I love it. I might try this sometime.

Gamemaster · Jan 25, 2011

Thank-you all for the positive feedback.

Project stats thus far
Start date: Sat, Jan 8
Foam: 6 sheets (2'x2')
Formed: Helm, L+R forearm, Torso, L+R handplate, L+R shoulder
Days off: 4
All pictures: http://s1087.photobucket.com/albums/j479/Puppyloveconnex/

Here are some pics of the arms, I did the left side first, modified my patterns and then the right side. I am happy with how the right side turned out.
The green is the left handplate

The left bicep and shoulder

I think the right side is nicer, I had to hack the left side in a few areas.

The grey detail is done with 2mm foam floor underlay.

The torso is almost complete, needs details and sanding, more pictures coming soon...

Mark VI high-def foam armor WIP

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