How to Make Warhammer 40K Cadian Cosplay Armor Part 2 - Pouches Grenades Leg Armor w/ Free Templates
by SKS Props
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What this video covers
This is Part 2 of an ongoing series by SKS Props covering the construction of Warhammer 40K Cadian Imperial Guard cosplay armor from EVA and HD-foam. The episode focuses on lower-body components — belt, pouches, frag grenades, and leg armor — using free downloadable PDF templates the creator provides on his website. Viewers are guided through cutting, shaping, gluing, and surface-finishing techniques, with additional painting and weapons coverage planned for later installments. The project is tied to a group build destined for Dragon Con.
Key takeaways
- ◆Free PDF armor templates are available from the creator's website and must be printed using Adobe Acrobat's 'poster' setting for correct scaling
- ◆This episode covers lower-body components: belt, pouches, frag grenades, and leg armor panels
- ◆HD-Foam combined with foam clay is the primary construction medium, finished with weathering products like Dirty Down Rust and graphite powder
- ◆3D-printable STL files for helmets, shoulders, rifles, and Imperial Aquila badges are linked as companion resources
- ◆Part of a group cosplay build targeting Dragon Con, with future videos planned for painting and weapons
Who this is for
Cosplayers and prop makers — beginner to intermediate — who want to build screen-accurate Warhammer 40K Cadian armor from foam using guided templates.
Tools mentioned
- • heat gun
- • hot knife
- • wood burner
- • utility knife
- • hobby knife
- • dremel
- • dremel flex shaft
- • leather punch set
- • cutting mat
- • mechanical pencil
- • hot glue gun
- • sanding drums
Materials mentioned
- • HD-foam
- • foam clay
- • EVA foam
- • PVC board
- • wood dowels
- • PVC pipe
- • contact cement
- • super glue
- • flexbond
- • plasti dip
- • cotton straps
- • buckles
- • graphite powder
- • Dirty Down Rust
- • Duralumen spray
- • Liquitex heavy body acrylics
- • BDU soft goods
- • holster belt
⚠ Safety notes
Use heat gun and hot knife in a well-ventilated area; exercise caution with sharp cutting tools including utility and hobby knives.
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