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Unread 07-04-2013, 05:35 AM   #1
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Expanding Foam over Worbla?

Hello everyone!

So I'm going to cosplay as Fi from The Legend of Zelda Skyward Sword.
Picture: http://fc06.deviantart.net/fs71/f/20...rb-d4lktqt.png

However, the only problem I have is the helmet. I've made the pattern, and I've been thinking of making the helmet out of Expanding foam, and the base out of Worbla. Will this work? Because I figured it would be easier to shape the Worbla pieces over my head.

But the only thing that bothers me is if the worbla will stay in shape when I put the expanding foam over it?
I want the helmet to be durable, so I'll put worbla over the expanding foam in the end, to get a smoother surface too.

Tips and tricks are appreciated! Thank you.
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Unread 07-06-2013, 09:53 PM   #2
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After doing a quick search on what worbla was.. Let me give you my opinion.

I've never worked with worbla.. but I have worked with a crap ton of expanding foam.. probably to much for my poor brain. If the material has a harder time holding its shape I recommend propping it over a base (you said your making a helmet.. so lets say over a ball) Slowly layer the expanding foam over it. So I would do a very small light layer over the worbla first. Give it a few hours to cure so it can tighten and hold its shape. Then layer and layer an layer. Expanding foam gets very rigid, but its very light. So start off very small at first then you will be able to layer more on later when its able to hold itself together.
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Unread 07-06-2013, 10:01 PM   #3
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Well, I have never worked with expanding foam. However, worbla will keep it's shape just fine in this situation. I'd make sure to use two layers of worbla for the base though. Much more sturdy than one.

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Unread 07-06-2013, 10:38 PM   #4
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I have worked with both and agree with what both the people above me say. (:
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Unread 07-07-2013, 05:10 PM   #5
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Thank you! This helped me alot.
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Unread 07-07-2013, 06:13 PM   #6
Satori Veda
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It should have no problem holding its shape. Unless it is heated it is pretty rigid. Expanding foam is not really heavy enough to cause the Worbla to collapse, but I would also recommend two layers for better rigidity.
Expanding foam is kind of annoying to work with though. Are you planning on bondoing it or wrapping it in aluminium foil before your paint job? Or are you just going to try to sand it smooth?
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Unread 07-08-2013, 06:51 AM   #7
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Satori Veda: I'm going to use paper mache and then sand it. Then I'll put another worbla layer over it to make it durable, plus, it will give a smoother surface to paint on after lots of Gesso layers!
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