I used a heat gun on this job, but in the past have used boiling water or a warm oven to achieve the desired effect. WARNING: This portion of the project involves using high heat. Look at any T-Shirt and you'll see what I mean. The back plate 's nape does not need to extend as low as the Chest Plate's neckline. You might as well cut the Back Plate while you're at it. Rotozip or Dremel type tools will make cleaner rounded corner cuts.
You'll have to make several deep, repetitive cuts. I used my band saw, but you can use a sturdy box cutter to cut through PVC foam board.
I then transferred the shape of the pattern by tracing the pattern onto the the black PVC foam board using a silver Sharpie marker so it showed up better on the black background. I made sure to cut the pattern slightly above the waist so he could bend slightly at the waist. I then cut it out of the calendar paper, pressed it to my son's body making sure he had enough room around the neck area and that he had adequate movement in the arms and torso. I went through a couple of iterations of chest plate shapes before I picked this shape. I first traced out the shape of one of my son's T-Shirts so I could get an idea of the scale of the Chest Plate. I brought home some large old 2009 wall calendars from work and used the back side as my pattern paper. Heat gun - you can use an oven or even a large pot with very hot water Packaging foam from a computer monitor box Tools: Velcro with peel and stick back)ģ disposable plastic ground beef containersġ disposable rotisserie chicken containerġ nylon web belt and plastic buckle (this was stapled to shipping a pallet, and was used for strapping) Hook and Loop tape with adhesive backing (i.e. (you won't use all of this)Ĥ PVC elbows - $0.80 each Pre-owned materials): Plastic soldier helmet from the local thrift store - $5.00īlack PVC Foam Board (Sintra) - approx $4.00 -ġ length PVC pipe - $0.98 for 10ft. Listed below are what I used, preceded by headings of whether they were purchased, pre-owned, etc.
You may already own most of these materials and tools. This Instructable chronicles the build of a Halloween costume for my 11 year old son.
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