Had to pick between cardboard or foam for a helmet build, went with cardboard and it was a mess

I was making a Mandalorian helmet for a con next month and my budget was under $20. The big choice was the main material. I could use foam floor mats from the dollar store, which would be about $8 for enough, or I could use old cardboard boxes I had saved up. I picked cardboard because it was free. I spent a whole day cutting, gluing, and layering with paper mache. It looked okay until I tried to sand it. The layers started to peel apart and the whole thing got warped from the moisture. My friend saw it and just said, 'Yeah, that's not gonna work.' I had to scrap it and start over. Has anyone else had a cardboard project fail and what did you switch to?

3 comments

3 Comments

harper2543mo ago

My buddy tried a cardboard shield for his Spartan costume last year. Total disaster. The thing got all soggy from spray paint and just folded in half. He switched to EVA foam from a craft store and it was a night and day difference. That stuff holds its shape and you can sand it smooth. Cardboard is just too unpredictable for anything that needs structure.

grant_ross271mo ago

Hold up, I gotta push back on this a little. Cardboard gets a bad rap but it is way more accessible for most people than foam. Not everyone has a craft store nearby or the budget for EVA foam, especially for a one time costume. Plus, you can get really clean results with cardboard if you layer it properly and seal it right, like Lucas said. I've seen cardboard shields that looked just as good as foam ones because the person took the time to reinforce the back with some wooden dowels or extra layers. It's all about the prep work, not the material itself.

lucas633mo ago

Wait he tried to spray paint straight onto cardboard? That's like the first thing you learn not to do lol. You gotta seal it with something first, even just a layer of mod podge or glue. But yeah, even then foam is way better for something like a shield. Cardboard warps if you look at it wrong.