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Brace yourself. 
Wirru’s cosplay armour MEGA TUTORIAL is here!
You will need to *right click>Open in new tab* to actually read it. 
Or see hi res version @

Part 1 - Foam shaping, Part 2 - Foam Detailing, Part 3 - Worbla

Feel free to ask questions here, or (preferably) on facebook 

Posted part of this the other day - here are all the parts! :D

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