This is what EVA foam looks like in its wild state. It's sold as anti-fatigue or playroom floor mats, and is usually about 1/2 inch thick. In theory you can layer it up to make things as thick as you want.
Time to cut! Luckily, I got some baddass shop shears for xmas that hungrily chomped through the foam! (Shop Boss, basically for all the things you CAN cut with sicissors, but aren't supposed to) Here you can see the mockup of the particular generator I'm trying to re-create, and the unfortunate diamond tread on my foam.
Fortunately, an orbital sander handily erases diamond tread. Ready to GLUE!
Then it was time for more precision cutting with x-actos and dremels:
Never one to miss the obvious, I couldn't overlook the facts that the in-game generator cores glow AND I had a lot of unused space in mine.
A trip to the toolbox and the attic, followed by more dremel time yielded some plexiglass with inlaid LEDs for edge lighting. The core of the generators have a peculiar texture, and I searched high and low for interesting metal hardware to cut up. Eventually I stumbled on chrome duct tape! Much easier to work, and has a pretty acceptable texture!
At that point, I got kinda psyched, and jumped a few steps without pictures. Whoops! The EVA foam is really easy to shape with some heavy grit sandpaper and a power sander. I also realized that I better add some structure for the belt-loop sooner than later, so I stuck some heavy zip-ties through with washers to stop them from pulling out. I was going to just let the battery control the LEDs, but I ran across a switch and couldn't resist.
IT IS ALIVE!
Now for the interesting part... trying to make it look pretty! The plan is to cover it in heat-formed craft foam, and then paint it with acrylic. In the end the LED's will be covered with a trim ring, so all you will see is the cool glow from the center of the generator. STAY TUNED!
Thank you so much for this! The wife and I are about to make our own B2 Costumes and we definitely need shields!
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