So I started on my halloween costume recently, i'm going to be going for a heavy armoured Jedi look. I decided to build the armor out of close cell EVA foam pads which i bought 6 in a pack for $10.
I started by getting some templates online, i decided to use some Mando armor templates from
http://mercs.firespray.net/forum/index.php?action=ezportal;sa=page;p=1. I took them into photoshop and did some alterations to make them a little heavier and less bounty hunter like.
Once the templates were printed I cut them out of cardboard and pieced it together for sizing:
Once i knew it fitted I traced the templates on EVA foam sheets, cut them out with an xacto knife and fitted them together.
After some work molding with the heat gun I actually attached them together, i originally tried using apoxy to piece them together but the dry time was just too long so i decided to use hot glue instead which works amazing. i managed to get a glue gun and ~40 glue sticks at the dollar store for under $5:
Once i put it together I added a few more pieces and trimmed some detail work which i forgot to take photos of.
As of right now i am working on priming the foam to prepare it for some bondo work, I read that bondo doesn't dry properly when applied directly to the foam.
Keep posted i will be posting updates every couple days.