lt. cupcake's design board

While there are many different techniques for painting foam cosplay pieces, this is the method I use for metal armor that works really well for me. So I have typed out exactly what I do in hopes that it will maybe help someone.

I specifically used this technique for foam Iron Man armor, but it can be used for most metal props.

warning: very pic and text heavy

Worbla sealing technique

I’ve been asked many times how I sealed the Worbla on my Wrathion costume for it to look this smooth. I don’t have progress pictures but I can explain since it’s pretty straightforward. This technique not only allows you to have a smooth surface, it gives you the chance to refine the shape and erase seams if, like me, you’re unable to form Worbla perfectly. Also, if you use a flexible paint and varnish on top, your piece will remain bendable without cracking.

Rub ‘n Buff Sampler - Color Review

I’ve been using Rub ‘n Buff as a metallic finish for my props for years, but recently at Gen Con I met an awesome Amaco rep who was giving out free samples and coupon codes (gencon2016 for 20% off a sample kit through their website).  So I picked up a sampler set of their full range of 12 colors and did a few test swatches.  “Sample” kit is a bit inaccurate, because I got a twelve regular 15 mL tubes of Rub n’ Buff.  This stuff is basically metallic pigment in solvent and wax which you rub on to a finely sanded or porous surface.  Because it’s wax-based it does not crack AT ALL, and the more you buff it the shinier it gets.

As for the colors themselves - gold matching has always been an pain in the butt for me so I was really pleased to see they had so many colors available.  The gif at the bottom was me attempting to arrange the colors from the most yellow gold tones to the most red gold tones.  They’ve only got two silver-tone colors, Pewter and Silver leaf, which are pretty similar except Silver Leaf is a little more liquidy and seems to have finer particles.  Spanish Copper is a basically a deep metallic brown, which strikes me as being great for grime or weathering.  The metallic particles in the Ruby color seem a little coarser than the other colors in the line, which might affect the final luster of a project.  Ebony, Patina, and Antique White all seem to be good for adding corrosion/weathering effects as well.

With the Gen Con code above, you can get a 12-pack sampler from Amaco’s website for about $45 shipped in the US, although it looks like you can get the same set off of Amazon Prime for $35.  Considering these retail for between $5-8 a tube, it’s a pretty good deal either way.  Here are a couple projects that I’ve used this stuff on, which are all basically thermoplastic/resin base -> Mod Podge coat -> wet sanding -> painted with Rub n’ Buff (no clearcoat or other finish necessary).

Robo-arm in Silver Leaf:

Yamask Masks in Gold Leaf:

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