DIY “Star Wars” Imperial Pilot Helmet on a Budget

#DIY: #IndyMogul shows how to build your own #StarWars Imperial pilot helmet on a low budget using repurposed toys, EVA foam, paint, hot glue & more!


Making Deathstroke Armor from EVA Foam

How to make #Deathstroke #costume armor from EVA Foam. A video tutorial by “Let’s Make Stuff” on YouTube:

Materials needed:


Advanced Cosplay: Making a Highly Detailed EVA Foam Gauntlet

Wonder what goes into making an advanced, armored gauntlet for a #costume or #cosplay? Cosplay Prop Shop created this set of 3 videos showing the process of creating a highly detailed gauntlet using the following materials:

  • Different thicknesses of EVA Foam.
  • Styrofoam.
  • LED lighting.
  • Translucent plastic cut from a Coca-Cola bottle.
  • Paints.
  • Cardboard. (Please note that this could also be done with EVA Foam.)
  • Wood-working glue.
  • Velcro.
  • Nylon webbing.
  • Elmer’s glue.
  • Faux fur.

Please note the following tools that are used to construct the gauntlet:

  • Heavy-duty scissors (instead of blades) for cutting the EVA Foam.
  • Hot glue & hot glue gun.
  • Dremel with various attachments.
  • Small paint brushes.
  • Sewing machine.

Video #1 (Constructing the Basic Gauntlet & Details)

Video #2 (LED Lighting, Finger Armor, Sealing)

Video #3 (Detailed Painting, Adding Faux Fur)

Selecting EVA Foam for Armor

If you’re planning a #costume or #cosplay that requires armor, one of the most common materials of choice is EVA foam. EVA foam (in its various incarnations) is a highly versatile material that (when not subjected to too much stress) can be repeatedly worn as part of a costume if it has been shaped appropriately.

Common questions that arise with EVA foam are what type of foam should be used and where can it be obtained. EVA foam comes in different thicknesses and types and is available from a wide variety of sources. Website “Otaku and Fit” wrote a wonderful article addressing these two questions, which we highly recommend:

Foam Buying Guide for Cosplay Armor