How to Build a Foam Cosplay Helmet

For his E3 costume builds, Frank worked with foam fabricator Evil Ted Smith to make three awesome cosplay helmets. Ted joins us this week to show how he turns sheets of cheap floor foam into shapely sci-fi and fantasy helms. It’s not too difficult!

Shot and Edited by Joey Fameli
Music by Jinglepunks

Comments (21)

21 thoughts on “How to Build a Foam Cosplay Helmet

  1. Norm & Joey, bang-up job on this video, thanks so much for this. Can’t wait to show my kids.

    You knew all the right questions to ask at just the right times. Keep it up!

  2. *A I actually bought all these from Leows. they discontinued theirs, so i bought out all the local stores. the Leows ones have less bubbles in them compared to the harbor freight or home depot.

  3. Great video! I know I’ll be watching this over and over as my kids want to make foam costumes for Halloween this year.

  4. EvilTed – the misnomer , more like HappyTed. Always good to see Ted sharing the knowledge -, go subscribe to his twitch and youtube!

  5. Very cool. I confess, I wasn’t interested in foam armor — until I saw your video. I like the process of visualizing 3D objects in 2 dimensional patterns.

  6. Great video! Very informative and fun.

    Is “Drop” a glue brand or is it just what the shop calls Barge contact cement?

  7. Any one know of a jig for the x-acto knife?

    I’m thinking acrylic base (to see work under it) just big enough for a couple of fingers on either side. a Slit in the middle of base to insert knife blade. Something like an upside-down protractor that you could set the angle. And the “pencil clip” part of the protractor could hold the knife handle & allow you to set the depth depending on how far up or down the handle you clip it in on.

    This way you could set the depth & slide the acrylic base along the top surface of (foam) and get an exact cut. & for the 45 degree cuts you could also lock in the angle & depth & just slide base across material. Would be great for those of us that are angularly-challenged & with not-so-steady hands.

    Alternative ~ just a small acrylic block with holes pre-drilled (Straight, 45 degree & ?? angles) to accept the knife handle. then a set screw to set depth & lock in. use it the same as above, insert knife to desired angle hole (no adjustability other than pre-drilled angles), set depth & slide block across top of material to achieve a steady cut.

    Adam ~ can we get on this? should be an easy enough build for someone of your talent. 😛

  8. Well stocked art-supply stores (such as those catering to architects/art-schools) have tons of x-acto handles/attachments that let you set set the angle and depth, or to cut grooves in material.

    Do a search for “Logan Foamwerks” and you’ll see all sorts of stuff that lets you make precise cuts in foam or board.

  9. Thanks, I will check them out. I did do a search on Amazon. com & Google before posting, but may have just not looked up the right wording. 🙂

  10. Hi, I’m currently working on a 3D-printable jig, which just clamps down in an X-Acto Blade. The first prototype works pretty decent and makes great 90° cuts. The nice thing is that the print takea only about 20min so I think I can produce a well working Version pretty fast. I’ll keep you updated.

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