Pretty self explanatory, is there a way to weather aluminum foil heavily (to make it look rusted) while still remaining flexible? I’m looking to cover a puppet with it, and I’m worried that paint will just crack. Is there another type of material I can use?

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I think the first thing to do is scuff up the foil to receive acrylic paint or try Krylon or rustoleum paint as one of these paints actually will rust with a patina process
I would perhaps line the inside of the foil with maybe tyvex to give it strength  
Do a test of coarse :)

Thanks for the input! I’m definitely going to try some Krylon.

This may not help, but I decided to try to make some small helmets using a scaled down version of the Cosplay armour that is all over YouTube. So I used 2mm EVA foam, which glued well with contact adhesive. I coated it with several layers of PVA and acrylic paint, finishing with using a little acrylic silver (I just love that it says 'not real silver' on the tube!!) to give a metallic sheen on edges and where appropriate. It works really well and is of course nice and light. But perhaps a shade too rigid for your purposes, unless you have some armour sections.

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