Simply amazing, I am new to the armor creating business and just picked up some foam. I plan to do something similar to this and I am asking for any tips you might be able to give me.
Cheers man. Yeah sweetaz no problem. First off buy a decent craft knife, it might be pricey but it will be worth it when u get to under way. The best tip i have would be to make your templates in paper first, and make sure they fit your body and proportions, then commit them to foam because it can be a costly mistake to jump straight to foam and realize it doesn't fit properly.
If you want to do freehand work but want it to be symmetrical, draw one half of your template out and then fold your paper down the middle and then cut it out while its folded, the half you already drew will become two parts because its repeated itself when u cut out the template while the papers folded, it saves heaps of time and means u only have to draw half each time. If you do this but need to see lines you've drawn on the other side, just go over the lines of the drawn side while its folded firmly and you'll mark the oposite side and then u just draw over that. Bam! , u got a symmetrical template
Another tip is when i wanted detail on a piece of armor, instead of adding or cutting pieces away id simply cut all the detail from one piece and then glue it back together at different levels, so raised detail would simply mean u glue the piece back where it was but the base of the side of the cut off piece would line up with the top of the width of the foam of the main piece, and then the opposite for indented detail.
Also dont be stingy on the hot glue, after u glue it together, flip it over and run ur glue gun down the seam on the inside, basically just squeeze a bunch of glue along the line, this will reinforce your armor.
Um also just make it as cheap as possible, that way u wont lose interest when the project hits hard on the bank account. My entire suit only cost about $180 dollars to make, so if i can budget, u can too
Hope that helped man