Halloween Universe
Costume TutorialsIntermediate

How to Make Warhammer 40K Cadian Cosplay Armor Part 1 - Chest and Shoulders Free Templates / Files

by SKS Props

Embedded from YouTube. This video belongs to its creator; Halloween Universe indexes it as a discovery resource.View original ↗

Difficulty
Intermediate
Length
12:19
Views
7,665
Published
Apr 2026

What this video covers

This is the first video in a multi-part series guiding viewers through building a complete set of Warhammer 40K Cadian Imperial Guard cosplay armor from EVA foam. Part 1 concentrates on the upper body — chest, shoulders, and forearms — using free downloadable PDF templates from the creator's website. The creator walks through template printing, foam cutting, shaping, and assembly, with finishing products and 3D-printable files for additional pieces also referenced. Future installments will cover lower body construction, painting, and prop weapons.

Key takeaways

  • Free Cadian armor PDF templates are available on the creator's website and must be printed using Adobe Acrobat's 'poster' setting for correct scaling
  • Part 1 covers chest, shoulder, and forearm construction using HD-foam and standard EVA foam-working tools
  • 3D-printable STL files for the helmet, shoulders, grenades, rifle, and pistol are linked separately for those with printer access
  • A full finishing workflow — including Plasti Dip, Flexbond, Duralumen, Dirty Down Rust, and graphite powder — is outlined across the series
  • The build is oriented around a group Dragon Con cosplay, making it suitable for collaborative or squad costume projects

Who this is for

Cosplayers of any experience level who want to build screen-accurate Warhammer 40K Cadian armor from foam, especially those planning a group costume for a convention.

Tools mentioned

  • heat gun
  • hot knife / wood burner
  • utility knife
  • hobby knife
  • dremel
  • dremel flex shaft
  • leather punch set
  • mechanical pencil
  • cutting mat
  • hot glue gun
  • sanding drums

Materials mentioned

  • HD-foam
  • EVA foam
  • foam clay
  • contact cement
  • super glue
  • Plasti Dip
  • Flexbond
  • PVC board
  • wood dowels
  • straps and buckles
  • BDU soft goods
  • Duralumen spray
  • Dirty Down Rust
  • graphite powder
  • acrylic paints

⚠ Safety notes

Use heat gun and hot knife in a well-ventilated area; exercise caution with sharp cutting tools and super glue.

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