This is the final shape of the foam for the right armguard of Kain's armor. This is the result of ~10 hours of carving out a foam block, and is only one of many pieces that need to be made. Below is what I started with:
Kain's armguard began as the 2 medium square green pieces of foam from the craft store (floral section has the foam). The lines are the rough outline for shaping. The next step was taking a hot wire tool (same section at the craft store) and carving big chunks off.
This is the result of carving out the outline, it still doesn't look much like an armguard. Next came sanding....lots of sanding.
This was the slightly more rounded version. Sorry that the next few steps don't have photos. It started taking shape, I got into it, and before I noticed that 5 hours were gone it was shaped. After this photo I drilled a hole down the center with a boring bit a couple of feet long. Then I pulled out a Dremel and used the sanding drum bit to carve it out until my hand fit through. That process took almost 3 hours until it fit. 2 more hours of carving details and the result was the first image. From this point on I'm using the sanding drum bit and the rotary tool since it works faster than the cheap hot wire cutter. Also, it was much easier working once the size of my arm was cut out (easy to see where I need to stop carving).
The next steps will be using body filler to create a smoother finish, sanding, finer sanding, primer, and airbrushing. It should create a finish like metal (since body filler is meant for cars).
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