DISCLAIMER: These steps are a GUIDE only. Always read the label of any product you use. Always wear your protective gear. This guide contains the use of resin, fiberglass, filler, spray paint and other solvents that can be HARMFUL or LETHAL if you do not take the CORRECT SAFETY PRECAUTIONS. I do NOT recommend that anyone under the age of 18 attempts this unsupervised. Do NOT fuck about with these chemicals, and don’t attempt anything unless you are absolutely sure that you know what you’re doing. WATCH a handful of videos on youtube. READ more than one tutorial from more than one person. Do not hold me accountable for any damage to your person or property that results from you being an idiot.
Armour (Card stage)
- Free Pepakura Software (Viewer and/or Editor, Online)
- Card as thick as your printer will take it. My smaller pieces were on 180gsm and the helmet on 250gsm. The colour doesn’t matter. (Hobbycraft)
- Scissors (Hobbycraft)
- PVA *or* a Glue Gun (Hobbycraft)
- Steel Ruler (B&Q)
- Scoring tool (can use a dry pen, back of a craft knife, whatever, Hobbycraft)
- Cutting Board (needs to be rigid to get good scores/folds, MDF offcut)
- Various Items for pushing recalcitrant card together. Something thin like a giant needle, small knife, sculpting tool or something in that vein.
Download Pepakura. (There are loads of tutorial vids about the ins and outs of using this program, I strongly suggest watching/reading at least two different ones before starting)
Find a PDO file of what you want to create. Google around what you’re looking for and something should come up somewhere, I found the Eldar stuff on 4shared.
Check the scale is correct. The really simple way to check this is to measure the body part the item is supposed to go on, and make sure the size in mm is correct. For example my bracers were initially too small, so I measured the length of my forearm and knocked off a few centimetres so I didn’t foul my elbow joint. Remember for helmets you need space for lining, ears, and so on, so if in doubt, add an inch or two.
Print your item.
Spend hours and hours and hours cutting out the pieces, scoring along the lines, and gluing them together with either PVA or a glue gun. The glue gun sets faster, but that’s a plus and a minus, as if you get it wrong you can fuck up the entire thing and have to reprint (a pain). PVA gives you time to check that the piece fits 100% before you let it dry on, but obviously takes a little longer. As I get more confident/faster at the assembly stage I might start to use a gun.
Eventually, you’ll have a completed item, in this case, a bracer. You can see my WIP Shoulderpad on the table.