![]() This is ‘white glue’ / wood glue, it dries clear, so it makes the pieces look all shiny and nice, and also makes them a lot more rigid feeling: When the pieces were all made I sealed them PVA which I got from a local DIY store. I used a hot air gun to bend/stretch the curves in the foam, which you can see the most in the helmet, this reduces the need for so many custs/lines which you would need if the material would only bend in one direction like paper: The details and lines in the pieces were made by staggering the edges of the foam, this is demonstrated in the second video above. I started with the helmet, although this isn’t the best advice if you haven’t built from foam before – probably best to start with a piece that has less tight corners/curves like the chest plate. The template for each piece was modified from the Pepakura files as demonstrated in the videos above. Here are some in progress pictures of the foam pieces, click for bigger versions. There are some YouTube videos about this, or scroll down for pictures and words: You can either buy the foam from a foam supplier, or use EVA foam floor mats, Yoga mats, and others. Note that Plastazote also often called EVA foam, or at least is very similar to it. The Pepakura templates for this came from here: The RPF I used approx three 2x1metre sheets of foam for the whole suit. Plastazote can be shaped and stretched with heat, which helped a lot with the faceplate for instance. All the parts were cut with a knife and stuck together with hot glue. This is a high density foam which weighs 45KG per cubic metre. I built the suit out of 10mm thick Plastazote LD45 foam. This page is about the foam build stage of the project, check out the main project index for the rest. ![]()
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