I am trying to find an inexpensive way to build up a proton pack, What kind of foam works best? Also I have heard that when using foam for crafting that spray paint can quickly eat away at it, what have you found works best in preventing that from happening.
I’ve found that using a urethane resin over the foam works pretty great.
A lot of people are building with EVA foam now. You can shape it with a heat gun, drill it, cut it with a heat knife or razor blade, and seal it with mod podge, or spray tool dip, or just spray paint it normally. (And if you buy the black and like the matt finish, you can leave it unpainted.)
The most popular source for it is those anti fatigue mats with the puzzle edges at Harbor Freight, though its carried at many places now as well. (And sometimes in assorted colors)
I used it for the first time last year for Samhain’s Cowl, and really loved the stuff.
We used the pink housing siding (the stuff with the Pink Panther on it) and then used Krylons H2o satin black paint.
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I used that insulation foam on our packs as well, and used water washup house paint to skin/paint them without issue. You just need to use something thats water based.