Foam Armor Construction Pictures
An opportunity arose to make some foam armor for a friend. The armor is that of Erza Scarlet from the cartoon Fairy Tail. I think it turned out better than my AOL disk armor.
Full Build, Front
Full Build, Side
Full Build, Back
Laying Pattern on foam
Cut Pattern
Epoxy-Glued Chest Sides
Chest Piece Assembly
Frontal Chest Piece Assembly
Shoulder Velcro Idea -no plastic in final version
Sides glued
Abdomen Bands Idea
Assembled (according to pattern lol)
Abdoment needs flare out, construct compass for arc
Proper Band Shape
More Bands
Shoulder Freeform Pattern!
One Shoulder Plate
Each level of the shoulder is different size.
Testing the size. -still unfastened/unglued
Leg ornaments -glued two layers together, heat mold them
Rotary tool carving results
Finished leg ornaments
Banding Fasteners - goal of allowing movement (post screws)
More Banding Fasteners
Top Band to chest attachement -allow for movement
Chestplate Neck Freeforming -also, modified chest for breathing
The pieces no paint
The math for the bands -think slices of cones :D
Closeup of Collar
Starting the Gesso
Gessoing the Bands
Shoulder Gesso, coat 2 -foam so thirsty. Getting Heavier.
Chest Gesso
Shoulder Gesso, coat 3 -only visible parts get paint for weight
Priming the Bands
More band Priming
Ornament Priming
Chest Priming
Shoulder Metalic Base! -silver mixed with black
Painted chest and bands -lighter silver drybrush
Attaching bands to chest
Testing the Connections
Leather straps for ornaments -attach with post screws
Testing the Ornaments
Fastening the Shoulders
Connectors for the shoulders -velcro binding straps cut in two.
Finished Shoulders -rub n buff detailing on edges
Painted Emblem
Shoulder connector Test
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