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Pattern 1038 - Thor's Helmet

8/12/2015

12 Comments

 
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My first blog about all these new patterns is going to be working with the EVA foam, which is a material that was new to me. BUT, having made many prototypes for the toy industry new materials don't scare me.  My challenge was to figure out how to do it and do it in a way that would be easy for anyone to reproduce.

So, the kind of EVA foam I used is just craft foam, the kind you can get at Joann's or Michael's. You can get it much thicker, 1/2" or more (available at big hardware stores) and there are wonderful tutorials showing how to use it, but the thin kind was just what I needed for this project. And it's much easier to work with.

The photo above shows the wings for Thor's helmet before painting. Let me show you how I did this.

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The pieces are constructed by gluing several layers on top of each other, curving them while glueing. So, there are quite a number of pieces to cut. I traced around all my piece with a fine point Sharpie then used regular scissors for cutting. But, not my fabric scissors.
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The layers MUST be glued over a curved surface to  become head shaped. I was making a child and adult helmet, so I went to my kitchen and found two pots that were about the same measurement as a child's and adult's head.
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You can see I taped the edges of the bottom most layer to the pot, to hold the shape.

I used the craft foam glue that is sold by the same company that makes the foam, but any contact cement works.
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Don't move the pieces until they are dry. Because the layers were formed over a cylinder they will hold the curved shape.
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I'm testing the look and the fit before starting to paint.
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EVA foam is very porous and needs to be sealed before the final paint can be applied.

The areas that are going to be glued to the cloth part of the helmet need to be kept free of paint. Because my original plan was to use spray paint, I masked these areas off with painter's masking tape.  If you are a careful hand painter this tape isn't needed.

BUT, I found out spray paint doesn't work AT ALL. It's super messy and just kept soaking in and in and in, never really sealing off the surface.

The thing to use is GESSO or MODGE PODGE. 
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I wanted to make sure the part that curves around the cheeks was going to stay nicely shaped, so I wrapped it with muslin around my seam roll after the Gesso was dry enough to handle and let it sit overnight. I don't know if this step is necessary, but ... 
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Then I hand painted on a couple layers of silver craft paint ...
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and glued the pieces to the cloth helmet.
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Here is some glue waiting to get tacky enough.
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And then I can press the fabric on.
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TAH! DAH!
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Meanwhile I was also making the silver discs that go on Thor's chest.
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They are made the same way as the helmet pieces, but are much easier. Little squares of fabric with snaps sewn to them are glued to the backs so they can be removed for laundering. I imaging Thor gets rather sweaty going around being heroic and his outfit will need a washing now and then.
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Thor and Thor Jr. ... awwww!
12 Comments
Therese
8/12/2015 03:00:51 am

Can you explain the muslin part more? Are you gluing muslin to foam and using same glue?

Reply
Andrea
8/12/2015 03:43:17 am

Are you calling the cloth helmet muslin? Otherwise, I didn't use any muslin. Basically the craft foam pieces are made separately and then glued to the cloth helmet. I used the same glue for both. But, you should test whatever glue you are using on scraps of the foam and fabric to see what works best for you.

Andrea

Reply
Therese
8/12/2015 04:35:45 am

Ohhh, I see now. I read the commentary without getting a good handle on what you were referring to by looking closer at picture. You use the muslin to secure the piece as it dries around the steam roll. I thought you were lining the entire helmet with muslin. Thank you for your time. Love your creations!

Jen in Oz
8/12/2015 09:22:03 pm

Ooh! I wasn't planning on doing Thor (I tend to specialise in DC Comics characters) but I CAN use what you've shown as guidance for making a Big Barda helmet (you can google the character if you like, I'm not sure how to attach a picture here) which is hopefully my next big cosplay project...
Thankyou!

Reply
Marietta Greene
8/14/2015 09:09:33 am

this is so much better than worbla! and easier to find - although I know where to order it from, local instant gratification of shopping my local craft store is easier

Reply
Thor Halland link
2/10/2016 02:18:34 pm

Hi;

How thick is the eva foam you are using? I am making the wings to attach to my cycle helmet..My Real name is Thor btw

Reply
Andrea
2/11/2016 10:49:57 am

Dear Thor,

It is 3 mm craft foam. They should have printed that on the envelope. but I see they did not!

Reply
Kathleen Sedgwick
7/13/2016 05:40:15 am

Hi, I don't see the instructions for the cloth helmet. did you use your own pattern for that?

Reply
Andrea
7/16/2016 07:26:40 am

The pattern and instructions for the cloth helmet should be in the envelope with all the other patterns. My blog is not a complete on line tutorial, but is meant to help out people who have purchased the pattern.

best, Andrea

Reply
ROSEMEIRE JANIZELLI
2/16/2017 10:46:48 am

Oi, boa tarde, gostaria de saber se vc pode me enviar os moldes do capacete do Thor, para que eu possa emprimir .Pois não sou muito boa em cópia de vista.... É que eu quero fazer o capacete para o meu filho de 5 anos desde já muito obrigado...E parabéns pelo seu trabalho.

Reply
Alejandra de Jesus Sifuentes Aranda
4/27/2019 08:58:18 pm

como obtengo los moldes ?

Reply
Andrea
4/28/2019 12:27:21 pm

No hay moldes.
Hay patrones e instrucciones en el sobre para cortar y pegar varias capas de espuma delgada que puede comprar en una tienda de arte. Necesitas obtener una copia del patrón. Eso lo explicará todo.

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    I am a commercial pattern maker who is now "sewing over 50"!
    I love to sew and hope to encourage others to come back to sewing.
    The water is fine!!

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