1. Open Cell (Upholstery) Foam Thicker, less dense than craft foam Thicker, less dense than craft foam Soft, compressable Soft, compressable Cut using scissors, craft knife, or kitchen knife depending on thickness Cut using scissors, craft knife, or kitchen knife depending on thickness

2. Open Cell (Upholstery) Foam Seal the foam – very difficult to paint directly on upholstery foam Seal the foam – very difficult to paint directly on upholstery foam White glue not a good option White glue not a good option “Flexbond” adhesive (multiple layers for a smoother finish) “Flexbond” adhesive (multiple layers for a smoother finish) “Super 77” spray glue for a rougher finish “Super 77” spray glue for a rougher finish Also the best option for gluing pieces together Also the best option for gluing pieces together Stays tacky – needs another layer before painting Stays tacky – needs another layer before painting

3. Open Cell (Upholstery) Foam

5. Insulation and Styrofoam Better for props than worn pieces Better for props than worn pieces “Hard” foam – doesn’t have give like craft or upholstery foams “Hard” foam – doesn’t have give like craft or upholstery foams Easy to carve into shape with a sharp knife Easy to carve into shape with a sharp knife Specialized cutters available Specialized cutters available

6. Insulation and Styrofoam Use cardboard, dowel, or pipe for internal strength Use cardboard, dowel, or pipe for internal strength To avoid chipping and scuffs apply paper mache layer to seal the foam before painting To avoid chipping and scuffs apply paper mache layer to seal the foam before painting Be very careful when gluing or painting; many spray-on products and adhesives will melt the foam Be very careful when gluing or painting; many spray-on products and adhesives will melt the foam Always test first – OUTDOORS! Always test first – OUTDOORS!

7. Expanding Foam Designed to expand to fill cracks Designed to expand to fill cracks Can be used to build up volume on a prop then carved down into the desired shape Can be used to build up volume on a prop then carved down into the desired shape

8. Expanding Foam Pattern: make a cross-section shape of the prop out of cardboard Pattern: make a cross-section shape of the prop out of cardboard Remember to include a dowel for strength if piece is long or delicate Remember to include a dowel for strength if piece is long or delicate Cover the pattern area with expanding foam and allow to dry (~1 day) Cover the pattern area with expanding foam and allow to dry (~1 day) Flip and do the other side Flip and do the other side Using the cardboard shape as a guide, carve down the foam with a sharp craft knife Using the cardboard shape as a guide, carve down the foam with a sharp craft knife To seal, add a layer of paper mache or similar before painting To seal, add a layer of paper mache or similar before painting

9. Insulation and Expanding Foam

10. Expanding Foam

13. Other ideas… Crayola “Model Magic” Crayola “Model Magic”

14. Other ideas… Pool noodles and pipe insulation Pool noodles and pipe insulation

15. Other ideas… Pool noodles and pipe insulation Pool noodles and pipe insulation

16. Thanks…. Photos used courtesy of: Mai Sheri www.maishericostumes.com Mai Sheri www.maishericostumes.com Kudrel kudrel-cosplay.deviantart.com Kudrel kudrel-cosplay.deviantart.com Featherweight www.featherweightcreations.com Featherweight www.featherweightcreations.com ShuShuWafflez shushuwafflez.deviantart.com ShuShuWafflez shushuwafflez.deviantart.com VickyBunnyAngel vickybunnyangel.deviantart.com VickyBunnyAngel vickybunnyangel.deviantart.com Filougon filougon.deviantart.com Filougon filougon.deviantart.com Pan PANattheDisco.deviantart.com Pan PANattheDisco.deviantart.com Yavarice cosplay.com/member/115091 Yavarice cosplay.com/member/115091 Cole cosplay.com/member/8322 Cole cosplay.com/member/8322 Jennifer “Mai Sheri” Wynne 2012 For The Rusty Gear