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Submitted on
December 18, 2009
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TF2 Demo vest blueprints by greenzaku TF2 Demo vest blueprints by greenzaku
Feel free to download and use :)

I used about a square metre worth of thick, black, closed cell foam rubber from Clark's Rubber in Australia to make the vest itself, and a thin strip of foam rubber to make the side straps. The pouches are just boxes wrapped in duct tape. This was a rushed job so no time to make nice pouches!

I re-used the pouch from the sniper cosplay here: [link]

Other materials:

Contact adhesive (CHECK the description to see if it works on rubber! Some types will corrode rubber)

Box-cutter (the sharper the better. Even so, foam rubber will pucket easily...I just lived with it)

Six drink cans (Get big cans if you are a big person and small cans if you are small. Not rocket science!)

tape measure

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Foam rubber is bendable and rather elastic. And these measurements assume that you are wider at the shoulders than at the waist. So a lot of 'GUESSTIMATION' was at work here....treat the tutorial as a guide, not a bible, and accept that most measurements would only be correct to within +/- 2cm!!!

This was a rushed job completed in a day, so if I make improvements to the design, I will post a new blueprint.

Good luck!
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Domorussell Featured By Owner Oct 27, 2014  New member
This is awesome. I'm going to make this my Halloween costume.
mixxi90 Featured By Owner Sep 5, 2011  Hobbyist Artisan Crafter
if you wanna cut foam easy use a electric knife like this : [link]

we always use it for .. whats english word.. this french hard long white bread rofl to chop it in pieces

you get it really nice^^ no puckets anymore and else use a dremel
greenzaku Featured By Owner Sep 5, 2011
Thanks, I'll bear that in mind.
mixxi90 Featured By Owner Sep 6, 2011  Hobbyist Artisan Crafter
your welcome^^ me and my friends also struggled a lot with this problem until my grandma told me of this XD

and now it goes vroeeemmm!!
zofraniro Featured By Owner Jul 31, 2011  Hobbyist Writer
What else would work well besides the foam/rubber stuff? It looks stiff. Otherwise, good job!
Oh. The requirements of measurement... I'm not even 95 pounds, since I'm so tiny, would I need to reduce the size any?
greenzaku Featured By Owner Jul 31, 2011
There is similar foam material that you can buy from camping stores as camping mats. I would say you could probably get away with thinner material too because of your might even be able to get some thinner rubber material that is used for floor mats or friction mats from a hardware store. Otherwise you can simply substitute your own X,Y,Z etc measurements in here.
Gunsguru Featured By Owner Mar 29, 2011
Hey, curious, how big was the piece of foam?

Our local Big Lots is selling large pieces of foam for 18$ a roll at 46inx93in. Curious if maybe one of those would be around roughly what you used.
greenzaku Featured By Owner Mar 30, 2011
It sounds like it, I used a 1m x 2m piece for the main panels and 2m of thinner mterial for the straps. But you might like to get more...I weigh about 110lbs only '^_^
Gunsguru Featured By Owner Apr 3, 2011
Yeah, it was a spur of the moment thing, I'll try and make it work and work well.
rohaam Featured By Owner Jan 9, 2011
I hope you dont mind me makin use of this :O
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