Con Crunch Episode 4: I Am Iron Man

The Con Crunch series wraps up with Episode 4, available starting June 6. Register to watch it free here before June 21st, 2019, and you’ll be automatically entered to win an amazing prize from our sponsors.

Meet Nathan of On Fire Cosplay, who’s putting together a spectacular set of Iron Man armor for Denver Pop Culture Con. He’s already built most of the costume, but the helmet — perhaps the most important piece — still needs to be constructed. Join him and host Cheryl Sleboda as they transform flat pieces of EVA foam into a fully shaped helmet.

Some exciting techniques you’ll find in this episode:

Discover the tools needed to work with EVA foam.

Learn the best techniques for cutting and gluing foam together.

Get an overview of roto casting, or slush casting, the technique Nathan will use on his finished foam armor to create lightweight, inflexible resin casts of each piece.

Bonus: Learn about cosplay handlers, what they do, and why they are so vitally important to a cosplayer in a large or awkward costume.

BONUS Bonus: Get some tips from a con expert (spoiler: it’s me again!) about how to make sure your con experience goes smoothly by following the con cosplay rules.

How will Nathan’s final armor look once it’s cast and painted? Watch the episode to find out!