Halloween Universe
Costume TutorialsIntermediate

How to Make Fallout Cosplay Combat Armor Part 3 - Shoulder and Forearm - Free EVA Foam PDF Templates

by SKS Props

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Difficulty
Intermediate
Length
8:41
Views
4,935
Published
Jan 2026

What this video covers

Part 3 of SKS Props' Fallout Combat Armor series focuses on building the shoulder and forearm pieces from EVA foam, with free downloadable PDF templates available on the creator's website. The tutorial walks through cutting, sanding, and embossing foam to convincingly mimic the look of leather and metal surfaces. Finishing steps include sealing and painting techniques to achieve a weathered, game-accurate appearance. This installment builds directly on the chest armor covered in earlier episodes of the series.

Key takeaways

  • Free PDF templates for the armor pieces are available on the SKS Props website, printable via Adobe Acrobat's poster setting
  • Foam embossing and heat-shaping techniques are used to replicate both metal and leather surface textures
  • Plasti Dip and Flexbond are used to seal the foam before acrylic paint is applied
  • A Dremel and custom sanding drums help refine and detail the HD-Foam pieces
  • This is Part 3 of a multi-part series — earlier episodes cover the chest armor

Who this is for

Cosplayers and prop-makers with basic foam-crafting experience who want to build screen-accurate Fallout combat armor using accessible materials and free templates.

Tools mentioned

  • heat gun
  • wood burner/hot knife
  • Dremel
  • Dremel flex shaft
  • utility knife
  • hobby knife
  • mechanical pencil
  • hot glue gun
  • cutting mat
  • paint brushes (mop, filbert, liner)
  • sanding drums

Materials mentioned

  • HD-Foam (EVA foam)
  • foam clay
  • HD-Foam dowels
  • PVC board
  • wood dowels/PVC pipes
  • super glue
  • contact cement
  • Plasti Dip
  • Flexbond
  • Liquitex heavy body acrylics
  • clear Christmas bulbs

⚠ Safety notes

Use heat gun and hot knife/wood burner with adequate ventilation. Exercise caution with sharp cutting tools and hobby knives.

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