How to Make Fallout NCR Cosplay Chest Armor - Free Foam Template - Paint Foam to Look Like Metal
by SKS Props
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What this video covers
This tutorial walks through building Fallout NCR chest armor from HD foam using a free downloadable PDF template. The creator covers the full fabrication process from cutting and shaping foam to assembling the chest piece, then dives deep into a multi-step painting and weathering workflow designed to make lightweight foam convincingly resemble battered wasteland metal. Techniques include sealing, base coating, metallic sprays, graphite powder, and rust effects to achieve an authentic worn look.
Key takeaways
- ◆Free PDF chest armor templates are available on the creator's website and are designed to print correctly via Adobe Acrobat's poster setting
- ◆HD foam is the primary material, praised for being lightweight and comfortable to wear
- ◆A layered paint approach — including Plasti-Dip, Duralumen spray, graphite powder, and Dirty Down Rust — creates a convincing weathered metal finish
- ◆Multiple adhesive options (contact cement, super glue, hot glue) are discussed for different assembly stages
- ◆The tutorial is positioned as accessible to both beginners and experienced prop makers
Who this is for
Cosplayers and prop builders who want to recreate screen-accurate Fallout NCR armor using affordable foam materials and accessible painting techniques.
Tools mentioned
- • heat gun
- • Dremel
- • Dremel flex shaft
- • wood burner / hot knife
- • large utility knife
- • small utility knife
- • hobby knife
- • leather punch set
- • hot glue gun
- • cutting mat
- • mechanical pencil
Materials mentioned
- • HD foam
- • foam clay
- • HD foam dowels
- • Plasti-Dip
- • Flexbond
- • contact cement
- • super glue
- • PVC board
- • wood dowels
- • Dirty Down Rust
- • Duralumen spray
- • graphite powder
- • Liquitex heavy body acrylics
- • mop brush
- • filbert brush
- • liner brush
⚠ Safety notes
Use heat gun and hot knife in a well-ventilated area; exercise caution with sharp utility and hobby knives.
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