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Foam and Worbla armour MEGA TUTORIAL by AmenoKitarou Foam and Worbla armour MEGA TUTORIAL by AmenoKitarou
Brace yourselves! The MEGA tutorial is coming. 
Part 1 Foam Shaping, Part 2 Foam Detailing, Part 3 Worbla

You will need to view full size to read this monstrosity
I hope this will help someone, somehow, someday~! 
Please leave feeback and share! Enjoy. 

P.S. PLEASE READ FAQs before asking questions in comments 

- What kind of foam? Where do I buy?
EVA foam. 5mm thick. I buy it in the form of a gym mat from local malls. 

- What kind of glue?
I use contact adhesive (you can buy this at any hardware store). But hot glue also works~

- Where can I buy worbla?
If you are in Sydney, there is a place that stocks it locally called The Sarlacc Pit in Parramatta. If you are elsewhere... I have no idea. Google "Buy Worbla Online" maybe?

- I can't afford worbla. What can I do?
Follow the tutorial until the end of Part 2. Then seal and paint it as a foam armour. Part 3 is completely optional. 

- I tried this and it didn't work so well. 
Practice. Fail. Repeat. Learn.

- Video tutorial?
There is nothing exciting about listening to my voice while I do tedious things. So I assure you this is the best medium. 

- Commissions?
Yes. PM for details and quote.

- I thought you disliked worbla? 
I do. But since there are many people out there who love worbla, and I am working with it now, why not share some knowledge?
Add a Comment:
Hinonoona Featured By Owner Jan 25, 2016
Why use the worbla over the foam? Is it just preference? Can't you get a similar finish without the worbla?
VelvetRoseCreations Featured By Owner 7 hours ago
Personally, I think it is mostly preference. But adding Worbla (or wonderflex) makes it very stiff. So you can bump, drop, step on it and it wont get ruined. If it's just foam, it can bend and get creases or even crack your paint layer if not done well.
LucaLouise Featured By Owner Dec 23, 2015  Hobbyist General Artist
What do you use to glue the pieces of foam together? And what is the thickness of the foam? :)
LorenzoAndre Featured By Owner Nov 24, 2015
What is worbla?
EwiZew Featured By Owner Nov 19, 2015
What will happen if I just make that part with eva foam? If I have a "ready" armor with all lines and all, but no worbla on eva foam. Can it be good without worbla, too?
iAnubis Featured By Owner Nov 22, 2015  Hobbyist Traditional Artist
He mentions above that if you can't find/afford worbla, you can just paint it to look like armor and you're good to go -- the worbla part is optional. :) Hope that helps, and good luck with your armor. 
steave1425 Featured By Owner Oct 23, 2015  Hobbyist General Artist
That's awesome. Thanks for making. :happybounce:
karmaqueen588 Featured By Owner Sep 29, 2015  Hobbyist Digital Artist
You just solved so many problems for me. i love you so much right now~
LucaLouise Featured By Owner Sep 28, 2015  Hobbyist General Artist
Do you think this will work for a breastplate as well? I recently made this one:…
When I finally have enough money to afford Worbla, could I just cover the breastplate in the stuff like with your method? (I don't want to start over >.<)
StrawberrySunflowers Featured By Owner Aug 25, 2015  Student General Artist
You are an angel!!! Thank you! <3 
snoopygirl11 Featured By Owner Aug 17, 2015
Awesome tutorial ^^
NekoRushi Featured By Owner Aug 12, 2015   Artisan Crafter
Holy crap, this is GOOD. I need practice on foam shaping, rly bad
LoelJGrey Featured By Owner Jul 23, 2015
The BEST HOW TO WORBLA ever found!!! AMAZING! Thanks for sharing it with us!
puenn Featured By Owner Jun 30, 2015
great job!
Wait0wat Featured By Owner Jun 27, 2015
This tutorial will prove most useful when creating the Golden Fleece from "God of War III"
greywolfeone Featured By Owner Jun 23, 2015
does the contact adhesive give you more time to get the edges together better and have less gaping, thus giving you a smoother finish that will be filled in with the PVA glue finish before paint.  I am just starting to play with the foam and I tried hot glue on a large edge and had trouble getting a nice seam.
Ginsu85 Featured By Owner Jun 12, 2015
This is gonna be very helpful for what I have planned... thank you for the tutorial...
NatanThe6th Featured By Owner May 2, 2015  Hobbyist General Artist
Hahaha I love how you explained the steps :p :p great work.
Arsanni Featured By Owner May 1, 2015  Hobbyist Artist
what is this brown....paper?
NatanThe6th Featured By Owner May 2, 2015  Hobbyist General Artist
It's called Worbla, it's a thermoplast.
rwolf1970 Featured By Owner Apr 24, 2015  Professional Artisan Crafter
Thanks man, looking for some tips on my first foam project, nice work :)
KupiecKorzenny Featured By Owner Apr 17, 2015  Student General Artist
I've always been a bit intimidated by eva foam, but this seems to be simpler than I thought! (though still now easy, of course). Cosplay I'm working on requires pauldrons only (not full armor) so it's a good way to start :) Thanks a lot!
SupaaNeko Featured By Owner Apr 13, 2015  Hobbyist Photographer
Simple, yet really got the point across. Freaking love it.
R62 Featured By Owner Apr 8, 2015  Professional Filmographer
Dumb question, but I assume this can work for Halo armour templates as well? Just curious since it has a LOT of details too :P
DesignerTJP Featured By Owner Mar 12, 2015
Hi! Great FX Shop Humor you have! I can feel your pain that you've been up at 3:00am several times on your cool projects. Thanks for your Tutorial!
OceanPirate Featured By Owner Edited Feb 23, 2015  Hobbyist Digital Artist
For foam, should we use EVA foam or would craftfoam work aswell? I use a 6mm craftfoam, even for details,but when I try to bend it, it won't allow me to,so now I'm stuck with a lot of seams in my details. I readed about using hot glue....How does that work? Putting hot glue on the seam,and pushing it together?
Kiteera Featured By Owner Feb 16, 2015  Hobbyist General Artist
Loved this! I'm in the beginning stages of a Star Wars: The Old Republic cosplay. I found plenty of helpful tips in here, thanks a million!
KiraVanndrea Featured By Owner Jan 29, 2015  Hobbyist General Artist
Thanks for the great tutorial!
Markonator Featured By Owner Jan 20, 2015  Hobbyist General Artist
Funny+helpful=perfect! :D
SeeKaz Featured By Owner Dec 14, 2014
Aweee-ssoomee ,amazing :D :D
Wild-Fire-1187 Featured By Owner Dec 12, 2014   General Artist
If I may place a recommendation: Harbor Freight Tools stores sell EVA foam sheets, 12x12 feet for $8. It's good foam, used for workshop floors, and you get a good lot of it for a good price.
CrystalArwen Featured By Owner Dec 2, 2014  Hobbyist Artist
Hello, this tutorial is awesome! Can I translate it to russian an post into russian cosplay community on ? I will add a link on your Deviantart
AmenoKitarou Featured By Owner Dec 4, 2014  Hobbyist General Artist
Sure can!!
Can you also link please?
I am much more active there and much more likely to reply to questions :)
jupiterelite Featured By Owner Oct 20, 2014
How do you heat the Worbla???
AmenoKitarou Featured By Owner Dec 4, 2014  Hobbyist General Artist
... with a heat gun
modesty Featured By Owner Oct 17, 2014  Hobbyist Digital Artist
THAT'S how you do the stupid lip thing. Brill. Thanks so much for that.

And yeah, I never thought sandwiching for worbla was a good idea either.
Thanks again!
AmenoKitarou Featured By Owner Dec 4, 2014  Hobbyist General Artist
yeahhhh it took me years to finally do it right!!!! It's so shit D:
monkaf Featured By Owner Oct 15, 2014
This is a great tutorial! I have a question regarding just making foam armor. Do you have a way to get cleaner edges w/o using worbla? I cant afford it and I would like to make the best looking armor I can with what I have. Any tips?
AmenoKitarou Featured By Owner Dec 4, 2014  Hobbyist General Artist
I like to avoid hot glue, and use contact adhesive. Once the seams are pressed together, I go over it with a heat gun and squeeze the seams tighter and cleaner to each other with my fingers. 
SadistOkita Featured By Owner Oct 14, 2014
I really love your hard work! Amazing! hihi <3
AmenoKitarou Featured By Owner Dec 4, 2014  Hobbyist General Artist
Thank you :)
robroydude Featured By Owner Oct 1, 2014
Talent and patience, I lack them, therefore I will live ficariously thru you. :)
madizzlee Featured By Owner Sep 29, 2014   General Artist
This actually just taught me everything I've been curious about!! I really want to try making some Worbla armor, but I had no idea how! Thanks so much for this!!
AmenoKitarou Featured By Owner Dec 4, 2014  Hobbyist General Artist
Thank you! Good luck with your costume!
Isavien Featured By Owner Sep 18, 2014
This is the best tutorial ever! Not even tutorial ... This is just the best of best :D 
It's good to have a laugh before all the sweat and tears and glued fingers :D
AmenoKitarou Featured By Owner Dec 4, 2014  Hobbyist General Artist
Thank you :)))
joshuainthebox Featured By Owner Sep 9, 2014  Hobbyist Artist
Helpful and I love the sense of humor!  So many tears... Kudos!
TenshiHime13 Featured By Owner Sep 8, 2014
Thank you so much for this.  I've been trying to figure out how to make my armor for a Lady Paletena cosplay and you just answered all of my questions!
MaxieMarauder Featured By Owner Sep 6, 2014   General Artist
What's worbla?
deomew Featured By Owner Sep 2, 2014  Hobbyist
I only have 2 months left till a con, and I was going to make a basic cosplay without the armor. But now that I've seen this, I'm most likely gonna try to make at least the foam versions.

Cheers for the guide!
Add a Comment:


Submitted on
July 13, 2014
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