I'm doing Solaire of Astora as my first cosplay. Everything is going well except the helmet so far.
I've patterned it out and it seems like it's looking good. However I have no fucking idea how to translate it into thermal plastics, specifically worbla.
My sister has a shit load of it, as well as ~2mm craft foam. However she says to use EVA foam instead of craft for a majority of the piece.
The pattern is too big for one piece of eva, and I reckon the added thickness will result in too tight of a fit on the inside.
I thought perhaps just adding worbla "pillars" on the inside for extra support.
Thoughts?
What I would do is use the patterns on the foam, I'd pick the eva as it works a tad better with worbla as it doesnt warp as bad when in contact with heat. Layer a sheet of worbla over each of the pieces and heat it over them (leave a little bit extra worbla to wrap around the foam a bit to secure it), You should be able to glue and tweak the pieces to make the helmet fit you.
That's what I'd do anyway but I'm a noob when it comes to worbla.
I made a solaire helmet out of craft foam and just layering pva glue to harden it... worked out pretty well.