Making Deluxe KLINGON Gauntlets from Foam – By Shawn Hussell

Tools/Supplies:

  • -Utility Knife
  • -Pins
  • -Heat gun
  • -marker
  • -contact cement
  • -foam ¼ thick (use whatever thickness you want this is just what I used)
  • -blueprints from KAG.org, print them out 
  • A step by step guide in pictures is in the gallery below


Directions: the printer-Print

-Print out blueprints and cut them out them out

-Ok, we are just going to stop here for a bit. I got extremely lucky and on my first print, they were a perfect size. Not everyone is going to be this lucky, I suggest one of two things:

A) Print out a size you feel might be close, follow the instructions but just for one gauntlet instead of two and then use this to resize (if need) the next set of blueprints.

B) Short on foam and don’t want to make one you likely won’t use? Well just print two side pieces and make the first gauntlet out of paper, foam is stretchy so you want the wrist hole small enough your fist barely fits. Because my gauntlets have a little stretch, I can get my hand in.  

if the material had no give in it then my gauntlets would be too small!

-That last point covers “how these things should fit,” they’re big, to begin with so why make them bigger than needed.

-Got your blueprints, they’ve been cut out.

Lay them down on the foam and pin them down, to keep them from shifting. Use your marker and trace the blueprints out twice, then flip the side piece and trace it two more times. I strongly recommend labelling them, the top of the side-panel blueprint is the right side. In my photos, I labelled right as 2, left as 1 and centre as

C. -Cut out the foam pieces on the inside of the line. Now heat form them, use my finished photo for referenced of pre-shaping, this will help (a lot) when glueing them to be close to their final shape.

-Consult your contact cement instructions, and follow the printer and two different images, the fit probably isn’t going to be perfect I and two different images, the fit probably isn’t going to be perfect I believe this was the cause of a lot of my problems. If you’ve never worked with contact cement, you might want practice glueing a couple of the left-over scraps together to get a feel for it.

Press the seams together carefully and start from the bottom working your way up. When you get to the wrist part you may have difficulties, try moving to the top and working back down, I found that helped me. You might have to hold the seams together briefly ensure a proper hold. If your lines aren’t perfect, well practice makes perfect!  If you look closely at mine they aren’t either, I’m opting to make new ones in the future rather than fix these. You can fill any gap with plaster or wood fill, I haven’t found something I like using yet, so I don’t have any recommendations. Qapla’!!

You now have gauntlets, go forth my fellow warrior and never again fear for your wrists or forearms; for they will forever be wrapped in foam!

Notes: I would recommend you look up videos on making foam costumes just to get a feel for this, I like Evil Ted, his first few videos are very insightful. I never made it to the tubing part knowing I’ll be replacing these. I plan on finding a very flexy tube or glue thinner foam around a small rope to make the tubing. That’ll come down to what you find.


  • Blog Author: Shawn Hussell
  • Layout: James Hams

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