How to Make Warhammer 40K Cadian Cosplay Armor Part 3 - EVA Foam Helmet w/ Free Templates
by SKS Props
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What this video covers
Part 3 of SKS Props' Warhammer 40K Cadian armor build series focuses on constructing the iconic Imperial Guard helmet from EVA foam. The creator provides free downloadable PDF templates on his website, designed to scale correctly across multiple paper sizes when printed via Adobe Acrobat's poster setting. The video is part of a larger group cosplay project aimed at Dragon Con, with future installments planned to cover painting and weapons.
Key takeaways
- ◆Free PDF helmet and armor templates are available on the SKS Props website, printable at home using Adobe Acrobat's poster mode
- ◆The helmet is built from EVA/HD-Foam using standard cosplay fabrication tools including a heat gun, utility knives, and contact cement
- ◆This is Part 3 in a full Cadian armor series — additional videos will cover painting and possibly prop weapons
- ◆STL files for 3D-printed Cadian accessories (helmet, shoulders, rifle, etc.) are also linked for those who prefer that route
- ◆The project is beginner-accessible, though a full product and materials list points toward a more complete intermediate build
Who this is for
Warhammer 40K fans and cosplayers of any skill level who want to build screen-accurate Cadian Imperial Guard armor from EVA foam using free templates.
Tools mentioned
- • heat gun
- • utility knife
- • hobby knife
- • wood burner / hot knife
- • Dremel
- • Dremel flex shaft
- • cutting mat
- • leather punch set
- • mechanical pencil
- • hot glue gun
Materials mentioned
- • EVA foam
- • HD-Foam
- • foam clay
- • Plasti Dip
- • Flexbond
- • contact cement
- • super glue
- • straps and buckles
- • PVC board
- • graphite powder
- • Dirty Down Rust
- • Duralumen spray
⚠ Safety notes
Use heat gun with care to avoid burns; work in a ventilated area when using contact cement, Plasti Dip, and spray finishes.
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