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Build time
1 day
Budget
<$200
Skill level
Beginner
Description

Make your own budget friendly Samurai Armor out of EVA foam. The patterns are available for a basic build but feel free to add your own artistic flair. This tutorial will cover how to make the helmet and the body armor.

Pattern templates are available here.

Tools required
  • Utility Knife (snap blades)
  • Contact Cement
  • Sharpie
  • Scissor
  • Scotch Tape
  • Cutting Mat (recommended)
  • Blow Dryer (optional)
  • Chip brush (optional)
  • Pin Needles (optional)
  • Dremel (or rotary tool, optional)
  • Drill Press
skills required
  • Safely handle drill press
  • Safely cut foam with a utility knife
  • Safely apply contact cement
images for inspiration
No images available
Supply list

Below is a list of all parts used to make this costume. In case you don’t already have them, we’ve included purchase links. Note the estimated cost reflects the cost of a full package (e.g. you may only need 5 screws, but the cost is for a large pack them).

Part Description
Costume section
est. Cost
Part description
1x 8mm EVA foam
costume section
Helmet
Est. Cost
$9.00
Part description
12x 6mm EVA foam
costume section
Armor and Tasset
Est. Cost
$66
Part description
2 cans Plastidip
costume section
All
Est. Cost
$31
Part description
Spray paint
costume section
All
Est. Cost
$22
Part description
3x 100ft paracord packs
costume section
Armor and Tasset
Est. Cost
$33
Part description
Scotch Magic Tape
costume section
Lacing
Est. Cost
$7
Part description
Liquitex Acrylic Paint
costume section
All
Est. Cost
$10
Part description
Pattern
costume section
Est. Cost
$5
Guide

Helmet (0:15):

  1. Print the respective pattern on 8.5 in x11 in sheet of paper.
  2. Join the patterns that span more than one page with tape.
  3. Cut out the paper patterns with scissors.
  4. Transfer the helmet pattern to 8mm EVA foam sheets by tracing pattern outline with a Sharpie. Include the dart lines, which will serve as “registration marks.”
  5. Cut the foam along the traced lines using a utility knife (DO NOT CUT THE DARTS--these are registration marks). Some edges will require a 45° cut. Follow the pattern instructions.
  6. Apply a small amount of Contact Cement on both edges of the helmet that have registration marks. Do the same with the “Bill” of the Helmet.
  7. Allow the Contact Cement to dry and become tacky to the touch before joining the seams.
  8. Connect the back pieces of the Helmet using contact cement as well.

Chest Piece (2:34):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the Chest Piece pattern onto 6mm EVA foam sheets. Trace the pattern outline with a Sharpie.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.
  5. Apply Contact Cement to the top and bottom piece of the chest piece. Give it a minute to dry before joining the two pieces.
  6. Repeat these steps for the back piece.
  7. Using a sheet of 6mm EVA foam, determine the length of foam you will need to wraparound the sides of your body. Refer to the video tutorial for more information (3:49).

Shoulder Straps & Neck Guard (3:14):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the patterns onto 6mm or 8mm EVA foam sheets. Trace the pattern outline with a sharpie. Some modification of the pattern might be necessary for proper fitting.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.

Tasset & Shoulder Armor (4:04):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the patterns onto 6mm EVA foam sheets. Trace the pattern outline with a sharpie.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.

Lacing (5:56):

  1. Measure and mark 22” long segments of paracord for the Tasset. You will need a total of 40 paracord segments that are 22” long.
  2. Make aglets (protective ends to prevent the cords from fraying/unraveling) using Scotch Tape by wrapping the tape around the end of the paracord and around each 22” mark.
  3. Cut down the middle of each aglets to produce 22” long paracord segments that have aglets on both ends.
  4. Repeat the aglet making process for the chest piece Tasset Hooks measuring, taping, and cutting 10” sections of paracord. Make 96 of these 10”cords.
  5. Repeat the aglet making process for the Shoulder Strap cords measuring, taping, and cutting 15” sections of paracord. Make 4 of these 15”cords.
  6. Loop the cords through your foam armor holes according to the video or to your liking.

Guide

Helmet (0:15):

  1. Print the respective pattern on 8.5 in x11 in sheet of paper.
  2. Join the patterns that span more than one page with tape.
  3. Cut out the paper patterns with scissors.
  4. Transfer the helmet pattern to 8mm EVA foam sheets by tracing pattern outline with a Sharpie. Include the dart lines, which will serve as “registration marks.”
  5. Cut the foam along the traced lines using a utility knife (DO NOT CUT THE DARTS--these are registration marks). Some edges will require a 45° cut. Follow the pattern instructions.
  6. Apply a small amount of Contact Cement on both edges of the helmet that have registration marks. Do the same with the “Bill” of the Helmet.
  7. Allow the Contact Cement to dry and become tacky to the touch before joining the seams.
  8. Connect the back pieces of the Helmet using contact cement as well.

Chest Piece (2:34):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the Chest Piece pattern onto 6mm EVA foam sheets. Trace the pattern outline with a Sharpie.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.
  5. Apply Contact Cement to the top and bottom piece of the chest piece. Give it a minute to dry before joining the two pieces.
  6. Repeat these steps for the back piece.
  7. Using a sheet of 6mm EVA foam, determine the length of foam you will need to wraparound the sides of your body. Refer to the video tutorial for more information (3:49).

Shoulder Straps & Neck Guard (3:14):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the patterns onto 6mm or 8mm EVA foam sheets. Trace the pattern outline with a sharpie. Some modification of the pattern might be necessary for proper fitting.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.

Tasset & Shoulder Armor (4:04):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the patterns onto 6mm EVA foam sheets. Trace the pattern outline with a sharpie.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.

Lacing (5:56):

  1. Measure and mark 22” long segments of paracord for the Tasset. You will need a total of 40 paracord segments that are 22” long.
  2. Make aglets (protective ends to prevent the cords from fraying/unraveling) using Scotch Tape by wrapping the tape around the end of the paracord and around each 22” mark.
  3. Cut down the middle of each aglets to produce 22” long paracord segments that have aglets on both ends.
  4. Repeat the aglet making process for the chest piece Tasset Hooks measuring, taping, and cutting 10” sections of paracord. Make 96 of these 10”cords.
  5. Repeat the aglet making process for the Shoulder Strap cords measuring, taping, and cutting 15” sections of paracord. Make 4 of these 15”cords.
  6. Loop the cords through your foam armor holes according to the video or to your liking.

Description

Make your own budget friendly Samurai Armor out of EVA foam. The patterns are available for a basic build but feel free to add your own artistic flair. This tutorial will cover how to make the helmet and the body armor.

Pattern templates are available here.

Tools required
  • Utility Knife (snap blades)
  • Contact Cement
  • Sharpie
  • Scissor
  • Scotch Tape
  • Cutting Mat (recommended)
  • Blow Dryer (optional)
  • Chip brush (optional)
  • Pin Needles (optional)
  • Dremel (or rotary tool, optional)
  • Drill Press
skills required
  • Safely handle drill press
  • Safely cut foam with a utility knife
  • Safely apply contact cement
images for inspiration
No images available
Supply list

Below is a list of all parts used to make this costume. In case you don’t already have them, we’ve included purchase links. Note the estimated cost reflects the cost of a full package (e.g. you may only need 5 screws, but the cost is for a large pack them).

Part Description
Costume section
est. Cost
Part description
1x 8mm EVA foam
costume section
Helmet
Est. Cost
$9.00
Part description
12x 6mm EVA foam
costume section
Armor and Tasset
Est. Cost
$66
Part description
2 cans Plastidip
costume section
All
Est. Cost
$31
Part description
Spray paint
costume section
All
Est. Cost
$22
Part description
3x 100ft paracord packs
costume section
Armor and Tasset
Est. Cost
$33
Part description
Scotch Magic Tape
costume section
Lacing
Est. Cost
$7
Part description
Liquitex Acrylic Paint
costume section
All
Est. Cost
$10
Part description
Pattern
costume section
Est. Cost
$5
Guide

Helmet (0:15):

  1. Print the respective pattern on 8.5 in x11 in sheet of paper.
  2. Join the patterns that span more than one page with tape.
  3. Cut out the paper patterns with scissors.
  4. Transfer the helmet pattern to 8mm EVA foam sheets by tracing pattern outline with a Sharpie. Include the dart lines, which will serve as “registration marks.”
  5. Cut the foam along the traced lines using a utility knife (DO NOT CUT THE DARTS--these are registration marks). Some edges will require a 45° cut. Follow the pattern instructions.
  6. Apply a small amount of Contact Cement on both edges of the helmet that have registration marks. Do the same with the “Bill” of the Helmet.
  7. Allow the Contact Cement to dry and become tacky to the touch before joining the seams.
  8. Connect the back pieces of the Helmet using contact cement as well.

Chest Piece (2:34):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the Chest Piece pattern onto 6mm EVA foam sheets. Trace the pattern outline with a Sharpie.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.
  5. Apply Contact Cement to the top and bottom piece of the chest piece. Give it a minute to dry before joining the two pieces.
  6. Repeat these steps for the back piece.
  7. Using a sheet of 6mm EVA foam, determine the length of foam you will need to wraparound the sides of your body. Refer to the video tutorial for more information (3:49).

Shoulder Straps & Neck Guard (3:14):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the patterns onto 6mm or 8mm EVA foam sheets. Trace the pattern outline with a sharpie. Some modification of the pattern might be necessary for proper fitting.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.

Tasset & Shoulder Armor (4:04):

  1. Repeat steps 1-3 of the Helmet section.
  2. Transfer the patterns onto 6mm EVA foam sheets. Trace the pattern outline with a sharpie.
  3. Cut out the foam pieces with a utility knife.
  4. Drill the pattern holes using a drill press.

Lacing (5:56):

  1. Measure and mark 22” long segments of paracord for the Tasset. You will need a total of 40 paracord segments that are 22” long.
  2. Make aglets (protective ends to prevent the cords from fraying/unraveling) using Scotch Tape by wrapping the tape around the end of the paracord and around each 22” mark.
  3. Cut down the middle of each aglets to produce 22” long paracord segments that have aglets on both ends.
  4. Repeat the aglet making process for the chest piece Tasset Hooks measuring, taping, and cutting 10” sections of paracord. Make 96 of these 10”cords.
  5. Repeat the aglet making process for the Shoulder Strap cords measuring, taping, and cutting 15” sections of paracord. Make 4 of these 15”cords.
  6. Loop the cords through your foam armor holes according to the video or to your liking.

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