Recently a friend rekindled my interest in costumes and props. I've made such items for both backyard cinema productions and “the big leagues” including specialty costuming on Zack Snyder’s Rebel Moon but I’ve never really studied EVA foam construction in detail.

Before the cosplay craze I was fortunate enough to learn a little about EVA foam costuming from foam suit veteran and inveterate maker Robert Miller, but I needed to refresh my memory.

Gratefully, there’s an embarrassment of riches on the topic available now so I dived in with a pattern from Evil Ted Smith, e-books from Kamui Cosplay and an incredibly detailed printed book on EVA foam construction by Beverly Downen.

The final piece is constructed entirely out of EVA foam of one kind or another. Primed in plastidip, painted with acrylics and alcohol ink and sealed with Krylon Matte Sealer (which I cannot recommend for it’s matte-ness, as you can see).