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Make: Props and Costume Armor by Shawn Thorsson

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3 EVA Foam

Turning Floor Mats into Armor

In the last chapter, you saw the amazing things you can do with paper and Pepakura. In this chapter you’re going to learn how to turn humble garage floor mats into a convincing suit of armor. This is the part where you’re probably thinking something like, “I don’t want to make a suit of armor out of foam! I want to make it out of hammered steel or a space-age carbon fiber and Kevlar composite with ceramic backer plates so it’ll be rock hard and stop bullets. After all, it’s supposed to be armor.”

If that’s what you’re thinking, you haven’t given it nearly enough thought.

Making your costume armor out of hard materials adds several orders of magnitude to the level of fabrication difficulty. It also ...

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