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