Yay!! It's finished! Three months of toil is finally finished!!
I'm so happy with how it turned out. I was able to give it a test Run at RadCon this weekend and it looked great as the durable for four hours before and surprisingly not as uncomfortable to wear as I thought it would be.
Now I can't wait for SakuraCon!!!
Here's a list of steps as to how I made the armor. I'll post a tutorial when I have time to make another pauldron.
I made my armor out of craft foam. I used the 6mm thick sheets like these. Although I found mine at Joann fabrics over by columbia center. That's the only place I could find the 6 mm sheets. I could not find them at Michaels or Hobby Lobby, although Hobby Lobby did have large 3mm sheets which I used for the dome of the pauldron, but that was the only time I used the 3 mm sheets[link]
For the lining around the armor I used Foam tape, the kind people use to insulate doorways and windows with.[link]
Then I covered the armor with about five coats of Kilz2 latex primer. This primer was meant to be used in doors so the toxicity it prett low, but I would still use a painters mask and gloves while applying it to be extra safe and work in a ventilated area while it is drying.[link]
And then I used Rustoleum Ultra Cover 2x Aluminum Spray Paint, beautiful smooth coverage. I would recommend doing this in the garage, outside, or at least next to an a wide open door to the outside and getting one of those painters masks that cover your nose and mouth, it's nother very healthy to breath in the aerosol of the paint: [link]
And finally covered every thing with liquitex varnish. This stuff was both protective and flexible. but tedious to wait for because it took 3 hours for each coat to dry and you didn't want to work it too roughly with the brush or it would dry cloudy instead of clear. I put down too coats of the gloss finish and one coat of the matte finish over the top and that gave me a nice shiny steel, but not too shiny, look. I found the liquitex at Hobby Lobby and Michaels, but not at Joanns. It was over in the section where they had all of the fancy paints and brushes. Make sure you get the flexible type liquitex it will say it is flexible on the back of the bottle.[link]