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Pro tip: switched from hot glue to contact cement on my Mandalorian chest plates and they survived a whole con without a single pop
I built my first set of Mando armor back in 2019 using hot glue on 6mm EVA foam and it looked fine on the shelf, but by hour three at the con in Baltimore the edges were lifting and one plate came off completely when I hugged a guy for a photo. Fast forward to this year and I redid the whole chest rig using Barge contact cement instead, and it made a huge difference. The hot glue cools too fast so you get these thick blobs that never really bond flat, plus it stays kinda rubbery and flexes loose over time. Contact cement needs 15 minutes of tack time and you only get one shot at lining up the seam, which scared me at first, but the bond is permanent and the seams sit totally flat. I did the math and the cement ran me about $18 for a can that did the whole suit, so it wasn't even more expensive than the bags of glue sticks I was burning through. Took me 3 tries to get the hang of clamping curved plates with tape while the cement set. Anyone else made the switch, or are you all still riding with hot glue for foam builds?
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