How to Make Foam Muscle Suits

By Alice Godfrey
Make your own muscle suit costume.

Heroes in movies and comic books all have massive chests and bulging muscles that ordinary people don't. Build a muscle body suit from foam rubber that will imitate the look of someone who works out constantly and can probably lift a car with one finger. The project requires supplies from a hardware store and a hobby shop. Just remember that your muscle suit won't fool anyone into thinking those bulging muscles are real.

Place the piece of foam rubber that will be the chest plate vertically on the table. Measure across the bottom of the rubber and make a dot at the halfway mark. Measure from the dot to each side of the rubber and make a dot at the halfway mark. Cut a 45-degree angled line from the dots on each side through the rubber with a utility knife. Remove the excess rubber.

Measure up from the center-bottom of the rubber to the top and make a dot at the halfway mark. Draw a circle on each side of the dot that has a diameter of 4 inches.

Place a piece of tracing paper on one of the circles and draw an outline on the paper. Trace the outline on a piece of rubber. Cut the outline out of the rubber with the utility knife. Repeat this with another piece of rubber. Run a line of bonding glue around each of the circles on the chest plate. Place each of the cut rubber circles on the two chest plate circles. Hold the circles against the chest plate for a minute.

Cut three lengths of foam rubber to the same width as that of the chest plate. Cut one-fourth of the length off one of the pieces, one-half of the length off another of the pieces and one-eighth of the length off another.

Measure down an inch from the dot in the center of the chest plate. Make a dot at this position. Measure down 2 inches and make another dot. Measure down 2 inches and make another dot.

Apply bonding glue against a side of each of the cut lengths of rubber. Place each of the lengths horizontally against the dots on the chest plate, with the longest length closet to the top, followed by the next longest length and followed by the shortest length. Let the glue set overnight.

Measure the length of your shoulder to your elbow. Cut a length of foam rubber that is as long as this measurement. Cut a second piece of foam to this measurement. Apply bonding glue to one side of one of the cut pieces. Place the other cut piece of foam on top of the one that has been glued. Repeat this entire procedure to make a second arm muscle pad. Let the glue set overnight.

Measure the length of your hip to ankle. Cut a length of foam rubber that is as long as this measurement. Make two foot pads in the same manner as was just done for the muscle pads.

Place the spandex suit on the table vertically with the neck farthest from you. Place the chest plate facedown on the table. Apply bonding glue to the back corners and center of the chest plate. Turn the chest plate over and hold it with the ab section at the bottom. Place the chest plate against the suit so that the abs line up with where they would be on a person wearing the suit. Press the chest plate against the suit and hold it there for two minutes. Let the glue set overnight.

Repeat this procedure with each of the muscle plates so that they are on their correct side of the arm sections of the suit. Repeat his procedure with the two foot pads so that they are on their correct side at the foot sections of the suit. Put the muscle suit on. Put on a shirt and pants. Look in a mirror and “flex” your new muscles.

Warning

Keep children and pets away from the bonding glue when you are using it.

About the Author

Alice Godfrey is a marketing analyst with more than 15 years of experience in her field. She holds a Ph.D. in social and personality psychology. Past positions include market research analyst at various advertising agencies and corporations. Her articles on a wide variety of issues relating to entertainment have appeared in numerous trade publications.