Cosplay: Making a Basic Armour Shoulder Pad | Step-by-Step

Step 1: Pattern Making

First is to make the pattern, I used white paper and a color pen to draw the first half of the shoulder pad.

Step 2: Translating Pattern

Then, I used the pattern and translated it into craft foam. Made two shapes out of the same pattern to make the complete shoulder pad. I cutted the pattern with a sharp Scalpel which helps me to cut curves in a more flexible way.

Step 3: Sanding

I used some sanding paper for the broders. It helps to seal and give dimension to the material.

Step 4: Contact Cement

Contact cement is an adhesive used to bond plastics, it is very resistant and doesn't left lumps when dried.Warning
The flumes are toxic and the product is flammable , so be sure to use it outside or in a very ventilated area. I use it with a respiratory mask, and then I keep it properly sealed outside my working area when not used for safety.

Step 5: Applying Contact Cement

Pour just a bit of contact cement through all the border of the first piece. Do the same with the other piece while the first one dries a bit, and then press both together until it bonds. This will help the shoulder pad to curve.

Step 6: Rings

The shoulder pad design has a hole in it, so repeating the first steps I made two rings for each shoulder pad. Plus I made two inserts with some black fabric and green neon fabric.

Step 7: Sealing & Priming

First I sealed with wood glue using a brush. Made a few layers and once it dried, applied a couple of layers of Gesso to prime it for acrylic painting.

Step 8: Painting

Painted all white and the holes wth fuchsia acrylic painting. Added the fabric on the holes and added a layer of matte sealer in spray. Finally attached the shoulder pads by sewing it into my costume.