How to Make a Trench Crusade Cosplay Helmet - Free Foam Templates New Antioch Lieutenant Sallet
by SKS Props
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What this video covers
SKS Props walks viewers through constructing a Trench Crusade New Antioch Sallet helmet entirely from lightweight EVA foam, using freely available templates from the creator's website. The build covers cutting, heat-forming, and gluing foam pieces into a wearable helmet shell, followed by sealing and a multi-stage acrylic paint process to achieve a grimdark, battle-worn finish. Gilding and texture medium add convincing metallic depth to the completed piece.
Key takeaways
- ◆Free downloadable foam templates for the New Antioch Sallet helmet are available on the creator's website
- ◆EVA foam is shaped with a heat gun and refined with a Dremel and hot knife for crisp detail
- ◆Plasti-Dip and Flexbond are used as sealers before painting to prep the foam surface
- ◆Liquitex heavy body acrylics combined with pumice medium and gilding create a grimdark metallic look
- ◆The tutorial is explicitly designed to be accessible to both beginners and experienced makers
Who this is for
Cosplayers and tabletop Trench Crusade fans who want to build wearable foam armor props, from enthusiastic beginners to seasoned prop makers.
Tools mentioned
- • heat gun
- • wood burner/hot knife
- • Dremel
- • Dremel flex shaft
- • large utility knife
- • small utility knife
- • hobby knife
- • hot glue gun
- • cutting mat
- • mechanical pencil
- • mop brush
- • filbert brush
- • liner brush
Materials mentioned
- • EVA foam (HD-Foam)
- • foam clay
- • HD-Foam dowels
- • Plasti-Dip
- • Flexbond
- • contact cement
- • super glue
- • Bob Smith super glue
- • Liquitex heavy body acrylics
- • Utrecht pumice acrylic medium
- • craftsmart gilding brass
⚠ Safety notes
Use heat gun and hot knife/wood burner with adequate ventilation and care to avoid burns; work in a well-ventilated area when applying Plasti-Dip and contact cement.
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