Q&A for How to Make Costume Armor

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What if I want to make a mask for a helmet?

Community Answer

You could get a plastic mask and alter it to what you like, then build foam on top of it.

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Question

How can I install LED lighting to my costume armor?

Cecilia Flores

Top Answerer

Talk to a professional cosplayer or even an electrical engineer about this, because lights can be very dangerous. They can break and glass can hurt you, they could burn you, they could start a fire, so much can go wrong. When you wear the costume, always have someone with you so that if something goes wrong, they can help you.

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Question

Could I make it out of cardboard?

Community Answer

Yes, but if it flattens, you will have to use more than a single layer of cardboard.

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Could I create it out of plastic and cardboard?

Community Answer

Yes. You could use anything durable.

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Question

How do I make armor out of metal?

Community Answer

You would have to physically bend the metal, which is very difficult. Also, it doesn't actually look that good. I would not recommend it.

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Question

What if I want to make a whole set?

Community Answer

Just repeat the process described here for every piece, but you'll need some kind of belt for leg pieces, or another way of keeping everything attached. There are many ways to do it, but the most popular is using velcro strips on certain parts of your body and attaching the armor there.

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Question

I want to make metal arms. Should I just buy gloves and put foam on top?

Community Answer

Yeah. You can sew or glue on Velcro to connect the pieces onto the gloves.

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Question

Is there any particular craft foam that's recommended to use?

Community Answer

EVA floor mats are the most versatile, but the thinner sheets found in the craft store work well for bracers or hand armor.

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Question

I was looking into creating a cosplay armor for Flavia (Fire Emblem Awakening). I have no experience with cosplay and am not that crafty. Would this be too hard for me? Any suggestions?

Cecilia Flores

Top Answerer

Anything with armor is very difficult and can be super expensive. Cosplay is quite expensive, and takes a lot of time and practice. Good cosplay costumes are very expensive to buy and may cost less to make, but DIY cosplay takes so much longer.

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Question

Can I make costume armor without cropped chest armor?

Community Answer

Probably, but if you don't want cropped chest armor, then you might have to make full-body (top half only) armor.

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Question

Is it possible to make this kind of armor for a Batman costume?

Community Answer

Absolutely, but with some caveats. Firstly, it depends what suit you want to make. The method described here is only suitable for making rigid armour, so it could be used to make the batman suits from the Arkham games, but not the film suits that seem to be a muscle suit and a cape. Secondly, I'd advise looking at how to make the fabric pieces of the costume (cape, cowl, etc.) before you dedicate yourself to the project because those will add an extra layer of complexity.

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