Build Materials & Sources
- 6mm EVA Foam, TNT Cosplay Supply
- C4 Foam Clay, TNT Cosplay Supply
- Black Leather
- Styrene Plastic Sheets
- Aluminum Chainmail
- Half-Round Pearl Beads
- Barge TF Contact Cement
Pattern Base:
Evil Ted’s Samurai Helmet (top section only)
Freehanded Parts
Build Process
Sorsha’s Helmet
Helmet Materials: EVA Foam, Foam Clay, Styrene, Leather
Sword Materials: EVA Foam with a 3/8″ Metal Core, Leather
Helmet Base Form
This is the earliest in the process that I started taking photos. I used the top part of Evil Ted’s Samurai Helmet as a base to work from. The brim, nose guard, and the fins were freehanded pieces from scrap foam.
Helmet Finial
The finial was fun to sculpt. I used a circle cutter to cut out rounds of EVA Foam and then stacked together and glued. I used a round toothpick to hold anchor all of the pieces and to center the point on the top of the helmet.
A Riveting Discussion
Preparing for attaching the “rivets”. I measured the sections and marked off rivet points at even intervals.
The rivets were simulated with Half-Round White Beads from Michael’s. I liked the rounded look better than googly eyes. The gaps were filled with EVA foam after wetting them down with water. I tried making the vertical pieces on the brim from Foam Clay, but they fell apart during sanding so Tom added strips of foam instead.
Post-paint photo. Tom did an awesome job with the coloring on this onen
Styrene Plastic sheets were used to create the diamon shapes for the helmet. I know I could have done some parts better here, but I’m still proud of the work.
The Finished Helmet
This is the completed helmet. Excuse the mess behind it. While there are some things I could have done differently with this build, I think it turned out fairly well.
