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DIY Tips: How to make your own foam costume in time for this year’s Mardi Gras

By Clark Rubber | 2nd February, 2024
DIY Tips: How to make your own foam costume in time for this year’s Mardi Gras

Creating foam costumes for Mardi Gras can be a fun and creative project. Foam is a versatile material that can be shaped and carved to create intricate designs.
Here's a general guide to help you get started:


  1. Foam Sheets: Purchase foam sheets of different thicknesses and colours.
    You can find them at craft stores or online. EVA foam is a popular choice for costume-making.
  2. Craft Knife or Hot Knife: For cutting and shaping the foam.
  3. Heat Gun: Used to heat and shape the foam.
  4. Contact Cement: To glue pieces of foam together.
  5. Velcro or Straps: For closures and to keep the costume in place.
  6. Acrylic Paint: To add colour and details to your costume.
  7. Paintbrushes and Sealant: To apply paint and seal the foam.


1. Design your costume. 

       Sketch out your costume design on paper. Consider the shape, size, and overall look you want to achieve.

2. Create Templates

Transfer your design onto paper or cardboard to create templates for each part of the costume.

3. Cutting Foam 

Use a craft knife or hot knife to cut out the foam pieces based on your templates. Be precise and take your time to ensure clean cuts. Our ask our Clark Rubber friend staff instore to assist in cutting your foam on site when you purchase you foam instore. 

4. Shaping Foam

Use a heat gun to heat the foam gently. This makes it more pliable, allowing you to shape and curve it as needed. Be careful not to overheat and deform the foam.

5. Assembling 

Use contact cement to attach different foam pieces together. Press them firmly and allow the glue to dry according to the product instructions.

6. Adding Details

Carve and shape the foam to add texture and details to your costume. You can also use additional foam pieces to create raised elements.

7. Painting 

Use acrylic paint to add colour to your costume. Multiple layers may be needed for a vibrant finish. Let each layer dry before applying the next.

8. Sealing 

Once the paint is dry, seal the foam with a clear sealant. This helps protect the paint and gives the costume a finished look.

9. Attachment and Closures

Attach Velcro or straps to secure the costume on your body. Ensure it fits comfortably and securely.

10. Test and Adjust

Put on the costume and make any necessary adjustments for comfort and fit. Make sure you can move freely.

Remember to plan, take your time, and enjoy the creative process. Foam costumes can be elaborate and eye-catching, making them perfect for Mardi Gras celebrations.

Images sources: 

Ruby Royale Official

Libby Hammer