Wow... finally someone using craft foam to build a spartan suit
I had originally planned to build mine this way - but my team had access to a vaccuforming table... and it was easier replicating suit with vaccuforming than with craft foam. However, I always knew it could be done.
I just can't wait to see this done !!!
You look like you haven't figured out the hardening process yet... my opinion on this is: why try to harden something that doesn't have to be ??? You're working with a flexible material and the fact that it is flexible is one of its good point. You'll be more confortable wearing your craft foam suit than any of your team member wearing their pep/fiberglass/bondo suit. I think you should be looking at making the craft foam stronger, not harder.
I suggest you look at using hot glue to strenghten the foam.
Coating the inside of each of your armor pieces with hot glue will make the foam strong enough not to tear under the stress of the straps and such you'll have to use to wear this suit. It will also give each pieces a nice added weight so they "fall properly" when worn. I've been making craft foam armor for the last 5 years and since I've been using hot glue to strengthen my foam - I've never had any problem with the armor falling apart or tearing. What I usually do is "double" every part of my armor with a second craft foam sheet (applied on the inside with a lot of hot glue). The glue strengthen the piece and you're not left with the sticky surface of hot glue when cooled because of that second sheet of craft foam.
Best thing is - hot glue is still flexible once cooled... which means you'll still keep a bit of the flexibility from the craft foam - which is gonna make a great suit.
Have a look at my website (see signature) to see some of my costume-mmaking tricks when working with foam. I've posted a couple of tutorials on there.
*** EDIT ***
First post since forum came back up - forgot to add signature
Here is the link to my website:
www.fullmetalsam.com