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06 Jun 2013 - 22:02103749
Another foam thread
So I'm planning on making the armour for Zero, the main unit in the game Zero Divide (see my costumes), using thick foam.

What I'm trying to work out is how to join the slabs of foam at angles other than 90° wihtout leaving massive gaps. I realise that I could cut the edges to the appropriate angle so that the join would be flush, but my practice attempts at this make it clear that getting the angle right (and consistent along the length) is going to be hard.

Does anyone have other methods or ways of getting a more consistent angle? Or should I go to thinner foam (and so a smaller gap) and put more effort into strengthening it?

Thanks in advance for any ideas.

06 Jun 2013 - 22:10103753
i found when doing my foam work that just cutting the angles free hand worked best and just hot glue together if you do leave gaps it depends on how you plan on finishing the foam weather or not you can convincingly fill the gaps.sorry if this isnt much help

06 Jun 2013 - 22:28103754
No, it's good to know if that really is the best way to do it. I had been hoping to do without much finishing, since you can get foam in exactly Zero's colour, but maybe it'll have to be seal + car paint.


16 Jun 2013 - 20:25104124
If you want to join at an angle, try cutting the edges if the foam pieces at a greater angle than you need it, don't have to be to precise, then carefully glue the edges to the correct angle, try using masking tape of the outside to stop hot glue seeping out or use super glue instead, then fill the gap left on the inside with more glue and scrap foam to reinforce it.

Another way if you don't really need a sharp edge is to cut a v shaped notch on the inside of the foam and bend it into shape (help it along with a heat gun if you need it, then glue it up on the side, that way you get an unbroken edge on the outside.

There are a lot of video's on you tube about building iron man and halo armour, I learnt everything I know from them, try this one

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