This was probably one of the most time-consuming parts of the armor crafting process. The type of foam I used is called EVA foam. It is very popular among cosplayers as it is relatively cheap and easy to work with. What makes this foam special is, when heated, it is easy to shape, and as soon as it cools down, it holds its shape.
The first step was to glue all of the front and back armor pieces to their matching piece. In order for this to work, I needed to glue one side together, and then have an open seam that allows it to easily come on and off. I tried to glue them so the open seams would be facing towards me, so I could reduce the visibility of those seams.
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After they were properly glued, it was time to begin heating and shaping the armor. The armor will be attached to me by being velcroed to a full-body suit, so the armor didn't have to be perfectly rounded all the way around my limbs. It took a lot of time to get all of these pieces shaped properly, but it was easily one of the most satisfying parts of this project.
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