Crafting Costume Armor

[Tribunal Power]

So I'm going to the release, and a party before/after, in costume. Part of my costume design includes durasteel armor psuldrons and bracers. I want to use some kind of hard plastic, not foam.

Does anyone have any experience with crafting Costume armor with plastics? Any tips or tricks on materials and tools?

Help me out and I'll pay you in pics.

 

[Darman Kebii'tra]

Before I begin, let me note that a lot of theaters are prohibiting certain costumes during showings. So if this is what you had in mind, you might want to reconsider.

Anyways, it sounds like you need Sintra to work with, but PVC is another good alternate.

The main tools that you'll need is a rotary tool or possibly a hacksaw. The latter of which I wouldn't recommend, but it's usable if you're unable to get a rotary. Use proper safety equipment like glasses and gloves so that you don't get a nasty cut. I know people joke about putting blood sweat and tears in a costume, but it's best to avoid them if necessary.

The other major item you'll need is something to heat up the plastic. I use a heat gun, but an oven will work fine as well. I would advise caution using either as you need to keep an eye on them. You want them to be hot enough to form, but not enough to start melting them. Also keep in mind that they'll be fairly hot once you pull them out, so keep safety precautions in mind on to prevent burns.

What kind of costume are you working on? Mandalorian? Rebel? Sith Trooper?
Its easier if you find some reference photos or sketch out what it is you want so that it all comes together how you want it.

Hope that helps.

 

[Tribunal Power]

Good call on the link, but my costume incorporates neither mask nor blaster, so I think I'm in the clear.

Yeah, PVC is what I've been thinking. Insofar as design is concerned, I think the pattern will be fundamentally the same as storm trooper armor, but will be painted and detailed much differently. The idea is a "gray jedi" look with a sort of rogue wanderer feel. Think of clone wars Obi-Wan, or a lot of the Jedi armor you'd see in TOR-- robe and plate combined. I already have the sewing patters made up for the fabric, now I just need the armor to round it out.

I hadn't even considered using an oven, that's pretty brilliant. How do you shape a pauldron (shoulder piece)? What can you use to form the sheet into that round semicircle shape of stormtrooper pauldrons?

I really don't want to do the whole mold creation/poured technique and everything. I realize it means leaving some detail behind, but I'm looking for the quick and dirty way to shape plastic and I like where your tips are taking me.

 

[Darman Kebii'tra]

You could still possibly make those without having to result to a total scratch build. But if that's exactly the kind of pauldrons that you want, then I would recommend looking to see if there is an pepakura versions out there to use as a base. That raised section on the Shoulder piece is going to be tough to do with pvc. You might be able to pull it off with some worbla, but then it may look wonky.

If you really want some fun (and it would probably be an easier process) you could just create the pepakura and then slap on some resin and bondo.