Had to pick between cardboard or foam for a helmet build, went with cardboard and it was a mess

I was making a Mandalorian helmet for a con next month and my budget was under $20. The big choice was the main material. I could use foam floor mats from the dollar store, which would be about $8 for enough, or I could use old cardboard boxes I had saved up. I picked cardboard because it was free. I spent a whole day cutting, gluing, and layering with paper mache. It looked okay until I tried to sand it. The layers started to peel apart and the whole thing got warped from the moisture. My friend saw it and just said, 'Yeah, that's not gonna work.' I had to scrap it and start over. Has anyone else had a cardboard project fail and what did you switch to?

2 comments

2 Comments

harper25427d ago

My buddy tried a cardboard shield for his Spartan costume last year. Total disaster. The thing got all soggy from spray paint and just folded in half. He switched to EVA foam from a craft store and it was a night and day difference. That stuff holds its shape and you can sand it smooth. Cardboard is just too unpredictable for anything that needs structure.

lucas6327d ago

Wait he tried to spray paint straight onto cardboard? That's like the first thing you learn not to do lol. You gotta seal it with something first, even just a layer of mod podge or glue. But yeah, even then foam is way better for something like a shield. Cardboard warps if you look at it wrong.