However, you don't want them to slip off while wearing them. The thing to keep in mind with these is that you have to be able to get them on and off. Hot glue the spikes into place in the cuffs. These were fun to make, but took a little more effort than just cutting and gluing. In all, we ended up having somewhere between 80 & 100 individual pieces of velcro sewn to the suit. Make sure there is good placement before sewing. Placement is really important to make this look good. The velcro does give a little flexiblity in the placement, but not much.
I started with the chest and worked down to make sure each piece worked together. I had to do this step by step, especially with the chest and abs and ribs. This is also why the adhesive velcro won't work. This will mark the spot the opposing piece of velcro needs to be sewn on. I drew chalk onto the back of the velcro and then placed the armor in the correct location while wearing the suit. 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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