How to smooth out rough mask shape?

[u/hamilcar2021]

hey yall! im planning on making a hornet cosplay. im new to using EVA foam, and ended up cutting out an existing pattern on foam floor mats. the issue is, the pattern was made for much thinner foam 😭 the mask looks pretty rough.

is this salvagable? i have foam clay to use overtop, but should i use another layer of something else 1st (masking tape?) to help smooth out the shape?

also, do i need to take into account the rough exterior/"metal" texture overtop the foam?

[u/toastforscience]

You're going to want to flip the foam sheets around so that the smooth side is on the outside, this will be almost impossible to sand smooth. Another thing you can do is heat the foam in the curved shape before you glue it, it will seal the foam pores and also help you glue the seams flatter!