I crafted a barbarian costume entirely from scratch via foam fabrication, patterning, sewing, and hand painting. The costume was based on concept art by Sora Kim.
MAKING THE MACE
Two styrofoam semi-spheres comprised the base. I used EVA foam tubing and strips to secure styrofoam spikes to the base, then coated the base with epoxy resin to harden it. After that, I sprayed a coat of Plasti Dip on, and finally hand painted the mace to look like distressed and battle-worn metal.
MAKING THE SHOULDER PAULDRONS
I patterned the dome-shaped base structures and layered on decorative elements made from foam and tubing. I hardened spikes with epoxy resin and glued them to a foam panel that I lined with fake fur. After hand painting everything, I glued the spiked piece to the main dome.
After selecting fabrics and fur trim, I altered a dress pattern to reflect the costume. I used a faux leather fabric to make the belt, and crafted decorative embellishments out of foam clay.
HORNED HELMET PROCESS
After many failed attempts, I got the pattern right for the helmet base. Then, I used foam strips and foam clay to sculpt details on the helmet and painted everything by hand with acrylics and oil-based paints.
For the shin guards and shoes, I created patterns from duct tape which I then transferred to foam and hand painted. I crafted coins out of foam clay and used leather strips and fur trim for detailing.
