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Unread 11-15-2012, 05:17 PM   #1
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Armor Seams

I'm new to working with cosplay armor, so I'm using a lot of trial and error in an attempt to get it to look/work right. Right now my problem is hiding the seams in the craft foam. I've tried using Gesso, which gives a nice smooth texture and doesnt dry quickly, which makes time for modification as necessary, but it seems to sink into the cracks i'm trying to hide. I've also tried working with plaster of paris, but it dries and clumps up too quickly. Provided is an image of the piece I'm working on currently trying to work with and an example of what i'm talking about with the seams

Any advice/tips/suggestions on what alternatives I can work with or other criticisms would be helpful
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Unread 11-15-2012, 05:31 PM   #2
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are u sealing it before u put the gesso on? as for side armor pieces like that ive heard of using bondo
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Unread 11-15-2012, 07:10 PM   #3
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Goldy uses a lighter and some pressure to get seams nice and tight, but his method is different in that he winds up covering his foam armor in vinyl. Here is the vid.

I typically make plastic armor for this reason since you can gap fill with bondo.
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Unread 11-15-2012, 08:08 PM   #4
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seams in foam armor have been most people's bane. Do not use bondo, as it is too rigid and brittle for foam, can eat away at it as well.

Best option I know is clean temples, a sharp knife, and this: http://costumesarecool.weebly.com/seamless-joins.html

great trick for hiding seams in foam.
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Unread 11-15-2012, 08:15 PM   #5
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i'm actually kinda in the same boat you are. I'm working on something that will have seams.

i'm glad to know someone tried the gesso and it didn't work.

My suggestion (and a thought) would be some type of air dry clay OR wood filler, although wood filler is kinda heavy. one more option would be caulk.

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Unread 11-16-2012, 01:44 AM   #6
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Unread 11-16-2012, 02:41 PM   #7
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Because the craft foam remains flexible, in order to hide a seam, you need to use a flexible product as well. Anything rigid you use will pull away upon the first flex, creating a crack, which is no better than a seam.

I've never tried this, but you might want to consider something like bathroom caulk. They are designed to fill cracks, and remain flexible, plus they have a long working time, so you can work it into the crack with out it showing. Stay away from silicone caulk; paint will not stick to it.
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Unread 11-16-2012, 02:45 PM   #8
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Thanks all for your suggestions. I'll try to put what I can to the test and see what I come up with! =D
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