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Submitted on
February 25, 2011
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Sizer's Helmet Tutorial by dust-bunny Sizer's Helmet Tutorial by dust-bunny
Here is a walk through of how I created my helmet "Stanley" for my Sizer cosplay.

A few tips when working with spray foam:

1. Work in small bits, if you spray too much at a time, it will become hollow or may not dry on the inside.

2. You can spritz the foam with water to speed up the hardening phase. Do this between layers of foam to ensure you don't get a hollowed out mess.

3. Spray foam sticks to everything, make sure you wear protection and do it in a place like a garage or outside.

4. Spray foam can be removed from skin while it is still wet with acetone. If you get any on you remove it immediately.

5. You can buy in expensive disposable razor blades at your local hardware store. When they become dull use a new blade, dull blades are actually more dangerous to use then sharp ones.

Hope this gives you some ideas of how to tackle your next armor project.
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VisualKei666 Featured By Owner Nov 7, 2012  Student General Artist
This is fantastic! I was just searching up helmet tutorials because I plan on doing Sakuyamon from Digimon season 3
I do have a question though- how would you suggest putting in like sunglass lenses into it and cutting away the foam into the shape?
Sakuyamon's helmet covers half her face and she has these black lense slits for eyes to see out of. I planned on putting a set of sunglass lenses in it to look out of. ^^
dust-bunny Featured By Owner Nov 13, 2012  Hobbyist Artisan Crafter
If I were going to do that I would probably remove the glasses from the frame, and then build the glasses frame into the helmet frame (with the wire and the at and the foam pieces) that way when I spray on the foam the glasses will hold a shape, and they you can simply carve away until you find the glasses frame and remove any foam from behind the lenses and clean out the inside, and then pop the lenses back in after you finish the clean up and decorating.

The other option would be to just make them helmet as if there were no lenses, then when you get the shape right, you can trace the lens shape to where you want it and carve out a hole to place the lens in.

It sounds like a really fun project, I will have to keep it in mind for some day!
VisualKei666 Featured By Owner Nov 14, 2012  Student General Artist
Thank you for the options!!!
I'm very grateful. I may end up going with the second choice since it sounds much less stressful ahahahaha
thank you so much again ^^
VFire Featured By Owner Jun 3, 2012  Hobbyist General Artist
That was amazing. I have not seen your work before and came across this tutorial. At first I was like, "Well this is ok." the final product blew me away! Great job!
dust-bunny Featured By Owner Jun 4, 2012  Hobbyist Artisan Crafter
Aww thank you. I often times feel this way about my work while in progress... Sometimes it is hard to picture how a project will turn out.

Thanks again for the compliment!
Shade-Fox Featured By Owner Jun 2, 2012  Hobbyist General Artist
I went ahead and started on my project, and it is worth noting:

spray foam does not stick to the slick shiny side of poster boards. =(
dust-bunny Featured By Owner Jun 4, 2012  Hobbyist Artisan Crafter
Spray foam has trouble sticking to any slick surface, that is why in most cases I tried to use the rough styrofoam balls, or the less slick side. Sorry I didn't mention it, hope you are able to recover!
Shade-Fox Featured By Owner Jun 7, 2012  Hobbyist General Artist
It's no problem! I got it figured out, luckily I had some fiberglass mesh tape so I applied that to my forms as fast as I could, and the foam hadn't dried in the nozzle so all went well. =)

It's a bit harder than I thought it'd be to get a nice even coat of foam on the base form. I have plenty of spots where the base is showing through, but it's probably nothing that a second coat won't fix.

I am using your tutorial and foam method to attempt a Megaman X costume for me and a Zero Omega costume for my fiance. =)
dust-bunny Featured By Owner Jun 14, 2012  Hobbyist Artisan Crafter
cool! I can't wait to see what you come up with. The carving is the fun part, when you see a bulbous hunk of foam transform into something awesome!
Shade-Fox Featured By Owner Apr 27, 2012  Hobbyist General Artist
first off, very cool tutorial! thanks for posting it.

i just have a couple questions, you say to work by spraying a bit at a time, then adding more later.
is there some trick to stopping the foam from plugging up the nozzle?
the man at the hardware store said the can was a one time use thing. >.<
how sturdy does your frame have to be? would the thin cardboard from popcan boxes do or would it have to be sturdier?

Thank you soo much for your time!
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