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Unread 11-24-2010, 06:47 AM   #65
FullMetalSam
Beyond Dream Cosplay
 
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Join Date: Oct 2006
Posts: 180
You should consider heat forming then.
It's the same thing as vacuum forming, without the vacuum.

All you need is a heat gun and something that looks like what you're trying to replicate. If you're working with foam or plastic, this can be done very easily. However, you'd get a smoother piece doing it with vacuum forming... but a little sanding and bondo can take care of imperfections
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