When my kids decided what they wanted to be for Halloween this year; Metroid’s Samas Aran (Varia suit) for the girl and Megaman X (light armor) for the boy – my husband, a home builder and old-school Nintendo fan ordered stacks of EVA foam to make their costumes.
I wasn’t too sure what to think when our dining room turned into a DIY cosplay crafting station in July and I had no idea that he’d somehow turn piles of what looked like gym mats into pretty cool costumes using a heat gun, spray-paint, and a few other supplies.
Wanna know how he did it? Check out his steps below:
- EVA Foam
- Retractable utility knives
- Heat gun
- Plasti-dip for priming
- Rustoleum aerosol paint for color
- Glue Gun
- bodysuits and black iron-on vinyl
- Caulk gun and caulking tube to close seams between pieces if needed
- old helmets
He went with EVA foam because it’s dense and porous and can easily be cut with razor blades. Starting with hand-drawn paper templates for every single piece – he then cut, heated and bent the EVA foam into shape. He primed everything with plasti-dip to close all the pores and get the material ready for painting. He ordered body suits (AKA unitards) for the kids on Amazon and lined them with Velcro to attach each piece of “armor” to the bodysuit. The Megaman X bodysuit was decorated with hand-drawn designs that were cut and secured with fusible black vinyl. The Helmets – an old Razor helmet, and sports helmet were picked up at a thrift store and modified. The shoulder “pads” on the Samus Aran costume were made out of styrofoam balls and EVA foam. The final touches of paint were first coated in color and then distressed using black acrylic paint and metallic paints to create scuffing and scratches.
The kids are stoked for Halloween – and my dining room has almost fully recovered.
I think it’s safe to say that the girl is officially over her Princess phase.
This one builds her own castles (or blows them up if she feels like it).
And their dad could totally have a cosplay side-hustle if the home design business ever gets boring. Check out his fun video here: