If you have been researching online to find different ways to make faux armor you will find that craft foam is an extremely easy and cheap way to create realistic looking armor. Is it lightweight and comfortable to wear.
This is the step-by-step process on how to make Princess Zelda Armor. Please understand that is my personal vision of what the armor should look like. As with all of my anime & video game costumes, I put my personal details to make it unique. This pattern is not 100% accurate to the game design. If you are looking to make a exact replica please feel free to draft your own pattern!
If you would like to use my pattern, you can purchase it on my Esty Store (this includes the pattern for Pauldrons, Crown, & Belt). If you would like to use my pattern, you can purchase it for USD $9.99 (this includes the pattern for Pauldrons, Crown, & Belt). The pattern (11 pages) you can print out on standard 8.5 x 11 inch paper. The patterns comes only in one size.
You will need these items to make the belt:
- Craft Foam – 2 sheets, 12″ X 18″, 2mm thick
- Hot Glue Sticks
- Hot Glue Gun
- Elmer’s Glue
- Jewelry Wire
- 4 Gold Rings
- 1 Blue Droplet Crystal
- 2 Blue Small Round Flat-Back Gems
- 1 Blue Large Round Flat-Back Gem
- Gold Acrylic Paint
- Black Acrylic Paint
- Gold Spray Paint
- Paint Brushes (Foam & Detail Brushes)
- Pen or Mechanical Pencil
Where I bought my supplies -
Crystals & Gems – Bohemian Crystal
Craft Foam Sheets, Hot Glue Sticks, Hot Glue Gun, Elmer’s Glue, Scissors, Jewelry Wire, 4 Gold Rings, Gold Acrylic Paint, Black Acrylic Paint, Gold Spray Paint, Paint Brushes (Foam & Detail Brushes), Pen or Mechanical Pencil – Michaels
- Print the PDF file “Belt”
- Cut out pattern.
- Lay the pattern on top of the craft foam sheets and trace around shapes, then cut them out.
- Using hot glue, attach raised details to each section. (Detail placement is indicated on the broken lines of the pattern) Exclude the pieces that are placed over the gems.
- Cover each section with Elmer’s glue & let dry. This will give the acrylic paint a good base to stick to.
- Score the center of the front detail piece with a fine tip creating a line that runs down the center.
- Paint all the pieces with the gold acrylic paint. It is up to you how many layers you would like to have and how distressed you want your armor to look. In my example photos, I first did a layer in gold acrylic, then painted all the crevices in black acrylic, then did a light dusting of gold spray paint to give it a bit of metallic shine, thennnnn went over it all again with another layer of gold acrylic paint. It takes a good amount of time, but the more details you put into it, the more dimension your armor will have.
- Hot glue your gems in place then set the large gem by hot gluing the foam detail pieces over it. Paint around the setting in black acrylic to give it more depth.
- In order to attach it all together, cut small strips of black foam and fold it over the rings. Make sure these little black tabs can move freely around the rings.
- Hot glue the tabs to the backsides connecting it all together. Use the reference photo below to see where to place them.
- Wrap wire around the crystal, then glue it to the back side of the triangle. Once it is in place, sandwich the wire with a foam tab.
- All Done!! One last tip about foam armor: If you ever feel like it is not the right shape, you can warm it with a hair dyer to shape it. Heat it until it is super bendy, then hold it in that shape till it cools.