I finally was able to measure the kids for some foam armor. I measured the arms and chest pieces. I even started one of the arms to see how the glue holds. So far, I’m not impressed with its strength but I’ll try more.
I’m using the basic patterns from http://www.tk409.com/tk409.html but the kids have decided that they want to be clone troopers not storm troopers so I’ll have to make some modifications on the fly.
The kids have black sweats from baseball and dark hoodies so the undersuits should be okay. I have about a dozen foamie sheets so we may need to get more.