After this is secure, you are ready for the next step. I used cardboard as a buffer to not dent the foam.

Next, put glue on the foam and the velcro and let sit for at least 30 sec. Then wipe it down so you have a clean surface. You have to sand through the plastic coating. I didn't do that on a few spots and the velcro comes off with minimal effort. Then, sand down the back of the foam where the velcro will be glued.

I suggest at least 2 pieces for each armor part, sometimes more. The first step is to cut the strips of velcro to sizes that will fit for each piece of armor. My wife and I were up very late many nights in a row to make sure this was done by Halloween. We decided to sew each little piece of velcro to the suit and glue the opposing piece to the foam. The only other option I had would take a lot more time to make work, but it WOULD work. Then, when I went to take the suit off, the foam started peeling off.īack to the drawing board I went. I even had two layers of shirts under it and it went through it all. Strapped it on with belts to keep it tight. In order to really have the pieces glued in the right place, I would need to be wearing it and waiting. The setting time for most fabric glues is at least an hour, usually more like 4. As can be seen in the picture, it didn't really work. As Halloween approached I got more and more worried that I wasn't going to be able to make this project work. Many people were saying to glue it directly to the suit, though there wasn't a lot of agreement on which type of glue was best. I got on many different costuming websites to see what others had done to attach foam to the fabric. This was the biggest challenge of the project.

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