How to Make Armor Out of Eva Foam

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Making armor from EVA craft foam can be an extremely effortless project -- or it can be complicated, depending on how much effort you want to put into the construction. You can make nearly any kind of armor from craft foam. Make any kind of armor from basic children’s costume armor to replica armor from high-budget fantasy movies. The texturing, painting and cutting that you do will determine the level of realism that the armor will have. To make the armor longer-lasting, glue a thin piece of fabric to the back of the foam to make it tougher.

Things You'll Need

  • Measuring tape
  • Paper
  • Pencil
  • Craft foam
  • Scissors
  • Hole punch
  • ½-inch wide elastic tape
  • Duct tape
  • Acrylic paints
  • Paintbrushes
  • Clear acrylic sealer
  • Measure your chest for the armor. Measure around the widest part of your chest, across the shoulders and along the waist or hips where you want the armor to end.

  • Make a pattern for the armor based on these measurements. You can make a variety of styles from craft foam; just make sure to keep each piece separate, such as the shoulder sections separate from the main body of armor. Make a front side and back side for the armor.

  • Trace the patterns onto craft foam. Cut out the shapes and label each piece so you don’t confuse the pieces.

  • Punch a small hole into each craft piece where you want to connect the armor pieces. You will want to attach the armor in two places along the sides, across the shoulders and at the top shoulder joint where the sleeves attach to the chest plate.

  • Tie a piece of elastic to each of the holes, connecting each of the armor pieces. You may have to reinforce the holes to prevent the foam from tearing. Use duct tape to reinforce the joints on the underside of the armor. You can also glue cloth to the underside of the armor to reinforce the joints.

  • Use a clay shaping tool to punch any designs into the surface of the armor.

  • Color the armor with paint. Allow the paint to dry, then paint an acrylic sealer over the top of the paint. Allow the armor to dry before using.

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