Claymore: The Blade Carrier
Probably the hardest part of the Claymore cosplay was the backpiece: the sword carrier. Options to make it ranged from EVA foam to learning how to create it in a 3D program and print to investing in vacu-forming. This was our first cosplay so I definitely have to say we vetoed vacu-forming - even though the one example with it clearly was top quality. In the end, we ended up using expanding foam and paper maché to build the backpiece. I started by taking the outline/general shape of the backpiece and cutting it out on EVA foam. Knowing that I needed the cape to be directly connected to it and would require a good amount of support, I cut it along its longest part - through the "wings" - and added a 1/4" diameter PVC pipe. On top of that, I created a 3D "guide" with a cross section of EVA foam on top. While contact cement is the recommended glue, I used E600 to attach the foam to the PVC and each other. Once dry, I used a can of Great Stuff Expanding Insulat...
