This is an experiment with FOAM. After a friend showed me a Pete Mander vid of him working on his Elite Halo costume, making the helmet out of foam. I wanted to try something that I could experiment on, to gain the experience of attempting to build armor out of foam. CRASH and BURN so to speak hands on training.
So far, I would not recommend this for trying to capture high detail (real life canon stuff). But I am still in the noob area of experience when it comes to working on armor period. Foam seems to be hard to shape and carve but who knows, maybe it will turn into something the more I experiment with it.
The biggest obstacle is getting the foam coated with something that will flex and yet have a hard glossy surface to be able to Rub and Buff.
After I saw CRUZER's CW Death Watch of Pre Viszla bucket thread, which is a super sweet job BTW.
Cruzer!! I decided to take on the CW Mando armor.
I printed off the WOF (I think every guy who builds a custom Mando is thankful for these), THANKS WOF. I printed off the plans and modified them as best I could (prior to the episode coming out) but I did pick up #115 SW Insider (pic reference) and after two weeks of messing around here is what I have so far.
My templates in paper.
First foam piece, I actually only had one internet reference for this two weeks ago. I didn't follow this shape exactly, I actually made it bigger and then trimmed it down to fit.
Thighs and gun in foam stage. I need to build the holster still.
Painted, and then Rub and Buff the right shin, guantlet, and shoulder. Rub and Buff both knees, as well. All other parts only have been painted with Plasit Dip (black) from Home Depot and then with Silver Vinyl paint from Auto Zone. They have not been RNB'd yet.
Shin on the left and both knees are RNB'd, the shin on the right is not.
Gauntlet on left is not RNB, right one is.
** photobucket being serviced right now ** ughhh
None of these pieces in the next shots have been RNB'd yet.


So far, I would not recommend this for trying to capture high detail (real life canon stuff). But I am still in the noob area of experience when it comes to working on armor period. Foam seems to be hard to shape and carve but who knows, maybe it will turn into something the more I experiment with it.
The biggest obstacle is getting the foam coated with something that will flex and yet have a hard glossy surface to be able to Rub and Buff.
After I saw CRUZER's CW Death Watch of Pre Viszla bucket thread, which is a super sweet job BTW.

I printed off the WOF (I think every guy who builds a custom Mando is thankful for these), THANKS WOF. I printed off the plans and modified them as best I could (prior to the episode coming out) but I did pick up #115 SW Insider (pic reference) and after two weeks of messing around here is what I have so far.
My templates in paper.
First foam piece, I actually only had one internet reference for this two weeks ago. I didn't follow this shape exactly, I actually made it bigger and then trimmed it down to fit.
Thighs and gun in foam stage. I need to build the holster still.
Painted, and then Rub and Buff the right shin, guantlet, and shoulder. Rub and Buff both knees, as well. All other parts only have been painted with Plasit Dip (black) from Home Depot and then with Silver Vinyl paint from Auto Zone. They have not been RNB'd yet.
Shin on the left and both knees are RNB'd, the shin on the right is not.
Gauntlet on left is not RNB, right one is.
** photobucket being serviced right now ** ughhh
None of these pieces in the next shots have been RNB'd yet.


Last edited by a moderator: