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How to Make a Foam Armor Chest Plate


Foam armor is a lot of fun and it is easy to work with. I have been doing a series of tutorials on how to make the various pieces and in this tutorial I do the chest piece.

This is one of a series of craft foam armor projects I have where I make a complete suit of armor. You can see all those projects here.

I also have a video tutorial for this project at the bottom of the page.

YoutubeWill has a youtube channel with over 750 videos on projects you can make. Check it out right here


Here is the Chest Piece we make in this tutorial

The completed chest piece


Earn a Certificate of Contribution!


If you make this project email me a picture! I will email you a certificate of contribution from stormthecastle.com You can print it up and hang it on the wall.




Materials Needed for this project:

  • Two sheets of posterboard (posterboard is large sheets of thick paper. You can buy it at Walmart, Drug stores, office supply stores and dollar stores.
  • Several sheets of craft foam. If you use the 12x18 then you will need four sheets. Smaller sheets can also be used. You will just need more of them. This is the exact foam sheets I ordered and use in this tutorial from Amazon: Foam Sheets 12"X18" 12/Pkg-Basic Colors
  • Strips of velcro You will need a maximum of three feet of velcro. But less is ok. I bought my velcro at a hardware store. Cost me about ten dollars. ( I found this on amazon. Pretty good deal because it is fifteen feet of it. Darice Hook and Loop Strip, 15-Feet, Black )
  • Some kind of glue. I use a spray on adhesive. It works really well for this project
  • Silver Paint. I use Rustoleum spray on metallic silver
  • Optional paint for the design you put on your chest piece. I use red paint for the templar cross

Note from Will: The Template and the tutorial are both absolutely free! But would you consider a donation of $1 to support my work? Paypal makes it very easy and safe. Click here to donate $1 - Every little bit helps Will to keep making great tutorials and templates. Thanks!


Let's Get Started!!

The First thing we are going to do is make our front and back pieces out of posterboard.


These are large pieces so I don't have templates you can print up but.... I do have large pictures with a grid. So you can look at my pictures and draw your pieces out on posterboard. (Templates are right here)

So Let's draw up these pieces!

Let's take a look at one of the pieces. This is the back piece and this is how to draw it up.

Draw a grid on your poster board.

Lay the posterboard horizontal like you see. Then draw a line right down the center from top to bottom.

Now, off this center line you create a grid. Each rectangle in the grid is three inches wide and four inches tall. My grid is in red so you can see it.


Once you have this grid you can use my picture to draw out your armor piece. Look at the picture of my armor piece and see how the lines are in relation to the grid. And draw it out the same way on your grid.

The chest piece is effectively broken down into small rectangles. You can easily copy these rectangles onto your poster board.

Repeat this process for the front piece of the armor, whether it be the men's or the women's. Those grid pics are here


The back pattern


Draw out the lines

Here I am drawing it out.








Now cut those pieces out! And there you go!

The front and the back


Let's Continue with the tutorial


Watch the Video Tutorial:


Foam sheets

Foam Sheets 12"X18" 12/Pkg-Basic Colors




Hook and loopDarice Hook and Loop Strip, 15-Feet, Black



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