More armors for Masamune

 Hello everyone!

Back on 13th February I started another armor making process for Masamune, this time his upper leg armor pieces.

Character reference.

I decided to roll with polystyrene once again and so I did some measuring and cut out two fitting pieces. I noticed after cutting that even though they had the right measures they weren't perfectly straight – oh well, it's not too bad...

Cut out polystyrene pieces.

Originally I had planned to make the armor out of several separate pieces –layered over each other– but I then remembered the amount of gluing failures I've done earlier with this plastic so I thought I'd do it another way – an easier way. So, with the pieces cut out I took a measuring tape and measured where each "edge line" would be and then just divided the length of the piece with the number of lines and started marking with a pencil.

Pencil marks added and yes, I used the knife box as a ruler.

On 5th April I decided to try if my idea would work or not – basically applying a line of hot glue on the lines I had drawn and then heat-shaping the polystyrene into the right shape. I had been going back and forth thinking if this would even work and being worried that the hot glue would get sticky again because of the heating; I figured that the only way out was to try it on a scrap piece.
But before the hot glue experimenting I wanted to check if I could cut a line into the plastic for the attachment purpose – basically a hole to pull the ties through. I had no proper tools for this so I tried with a kitchen knife. I had to use quite a lot of pressure and I managed to cut pretty deep into the plastic but on the other side it didn't go all the way through so yeah, in other words it didn't work out.

The side I cut on.

The backside. Didn't go through. :(

With that tried and tested I had to go ask stepdad for better tools; if nothing else I'll use the drill he has but maybe if there was something that would do a line instead of a hole it would be more convenient.
Well well, now back to the gluing – I took a scrap piece, heated the glue gun and carefully applied a thin line as evenly as I could manage.

I know it's beautifully straight. Not.

When the glue had cooled down I carefully tried to bend the plastic and the glue moved with it – no cracking or loosening or anything! The hot glue didn't turn liquid-ish again; it didn't move even when I was heating the side it was applied on. Only thing was that at the very edges a super small bit of glue softened and thus glued onto my glove so eh, I guess it could turn sticky again if heated enough or too close...
Oh well, I took the heat gun and shaped it the same way I would shape the actual pieces.

Success!

With confidence and proof that it would, hopefully, work as envisioned I began to work on the actual armor pieces. Next in line was to do five glue lines. Slowly. Carefully. Caaaaaaarefullyyyyyyyyyy.

One done, four to go!

It was more of a pain than one would think – I ended up with aching shoulders because I was doing it with my head almost in level with the table and the glue gun arm held up. Also constantly having to keep the same pressure on the glue gun's trigger (reason: have the glue come out as evenly as possible at all times) made my hand hurt and cramp; when I was working on the second armor piece's final lines it was hard to keep my hand steady, because of the shaking that occured when trying to keep the same pressure, aka not moving my hand from the trigger. It wasn't the best gluing experience but I still think it turned out pretty okay.
At some point I think the glue gun got too hot because the glue just flowed out without me even trying to get it out and it did this "glue bump - line - glue bump - line" pattern that was just not what I wanted so I took it off for a while to cool down. Also, when the "mouth"/tip of the hot glue gun accidentally touched the polystyrene it melted very slightly. Actually, I ended up noticing that you could use the glue gun even when it was not plugged because it took quite a while to cool down... xD

One armor piece done.

One 7th April I heat-shaped the armor pieces. It all went well except that it wasn't the easiest to get both pieces to bend an equal amount, but after some tries it worked out alright. The only mishap that happened was that while I was heating one of the armor pieces I accidentally moved my arm over a spot with a glue line and some of the glue stuck on my glove. It wasn't too bad though, I just grabbed some paper, wiped off the smeared mess on the armor and poked the remaining semi-hard glue back in place with my nail. No harm done.

One armor piece shaped.

I finished these armors today on 15th April. I had gone to mom's place because I needed to use the drill and the spray paints were there as well. I went to ask stepdad for advice about the drilling and after some brainstorming we agreed that the best approach to get holes in these things –for the attachment elastic bands– was to do several small holes in a row. Actually he did the measuring and drilling for me because one has to be very careful and well, he's kind and I'm derp.

Notice the pencil markings at the left and right corners.

Holes drilled.

Closer view of the holes.

Stepdad then went to fetch the utility knife so that we could clean up the drill holes and make room for the elastic ribbon to pass through. He also did the cutting part.

Cutting time ~

Trimmed hole.

Next step was for me to do the sanding. I used some 120 grit sand paper to even out the holes a bit more, you know, to make it less obvious that there were a lot of small drill holes. I also sanded all around the pieces to nicen up the raw cutting edges I made back when I cut these things out.

Sanding time ~

With that done I figured it wouldn't hurt to use some very fine grit sand paper to scratch the surface of the plastic very slightly to get it to take in the coming spray paint a bit better. Here we go!

My sand paper of choice.

Sanded surface.

Okay, so now my armor pieces had slight sanding dust on them. The thing to do now was to take some paper tissue, wet it with a slight amount of turbentine and cleanse the plastic by wiping it carefully. I avoided touching the hot glue decorations.

Turbentine.

So with the surface free from sanding dust, fingerprints and such it was time for the actual painting job. I used a semi-gloss black spray paint and sprayed away. Outside, of course, in a well ventilated area; this thing is not fun to inhale a lot of.

Spray paint coating recently added.

While I watched the spray paint dry I noticed these unsightly bubbles that had formed on one of the armors. I don't know where they came from but I certainly wasn't planning on letting them reside on my black goodness! I just took a paper tissue and wiped the surface above the bubbles. The bubbles went with it along with some paint that had not been set yet. I just repainted the wiped spots afterwards.

I don't like what I see...

... that's better.

Now I just had to play the waiting game and add new coats of paint when the earlier ones had dried. When the front was painted I turned the armors and painted the backside; when these had dried I took them inside and went to fetch the elastic ribbon that I'd use for attaching these things to my legs. Yeah, I cut four pieces of some black elastic and secured the ends with a zigzag stitch.

It's important to zigzag!

I then took one of the elastics at a time and started threading them through the holes in the armor and sewing them on. I quickly noticed that it was possible to sew the elastic on at one side with the sewing machine – saves time!

Sewing elastic in place.

What I also noticed was that to fasten the elastic on the opposite side was close to a physical impossibility – if you wanted to do it with the machine, that is. So, in other words, I just sewed one end of each elastic onto the armor by machine. Like this:

At this point I had to leave and go back to my apartment, but before I left I took with me some items for handsewing and some black thread. At home I sewed on the other end of the elastic by hand. I had to keep the stretch tight with one hand and sew on the elastic with the other but it all went well.

Sometimes handsewing is convenient...

Armors done I quickly put on my Masamune cosplay pants and put on the thigh armors – I'm surprised it actually works as well as it does! Sure that it doesn't look the most impressive ever but I'm satisfied with the results.

Quick armor test.

One thing's for sure though, when I finish this cosplay and wear it out to an anime convention I will have problems sitting down because of all the armors... and I will need help to dress. Outch.

Yeah, that's it yo! See you later alligator!

Samurai style torso armor

On 24th June I started working on the torso armor for Bakumatsu Renka Shinsengumi's Souji Okita.

Character reference

I decided to go with polystyrene even though I had a not-that-good experience with it earlier. I think I've learned some things about the material along the bad experience as well as the successful one. A bit wiser from earlier tries I thought polystyrene should be suitable for Okita's torso armor. I decided to do the armor similar to kendo armor, this because the backside and shoulders aren't shown anyway and it has pretty much the same shape.

Kendo armor - do

So I picked up my polystyrene sheet roll and started taking some measures and drawing on it. I drew one of the sides free-hand and used baking paper lol as a pattern to trace on and get the other side identical to the first.

Tracing

I must say cutting polystyrene -at least the width I have- is quite hellish.. especially curves.

Soon finished cutting

After cutting it out I went in front of the mirror and bended it over my body and OH GOD I DON'T EVEN. While the length and width were fine I had completely screwed up the "arm hole"/side curving and the placement of those two rising front.. things-or-whatever-they-are. I wondered why in hell I hadn't checked the fit in front of the mirror before cutting it out..? ._. Needless to say I couldn't use this one so I had to make another. I repeated the procedure with the necessary changes added. When I was done I had this:

Seems much better

I tried this one in front of the mirror and success!

After that I went up to the attic to check for any possible close-enough fabrics for the armor's upper pattern. I didn't found anything very similar but I thought this one snake skin-ish fabric was pretty cool for it. It has a nice sheen too and should look pretty sweet with the red spray paint under it. I didn't work on the armor any more for that day after getting the fabric.

Today (26th June) I continued working on the armor. The first thing I did was cut out a test piece of the fabric and take a scrap piece of polystyrene and well, hot glue the fabric on it to test if it would stick and stay.

Sits like a mountain, success!

Then I went ahead and made a pattern of the armor's upper part, where I wanted the fabric to be.

Pattern cut out

Fabric cut out

Next it was time to sand around the edges of the whole armor to get them nicer. After that was done I drilled holes into the armor for the ties because hey, I need to put it on somehow!

Armor after sanding edges and drilling holes into it

Luckily I happened to have almost a full can of red spray paint over from like... uh, 4 years ago when I did my first cosplay - Ichigo Kurosaki from Bleach. I had used red spray paint for his sword chain thingy and now I got to use it again for Okita's armor. So with the spray paint at hand I went outside, put up a working table and used a cardboard piece as cover and sprayed.  Many coats of paint later I had this:

I didn't waste much paint on the upper part because it would be covered anyway..

I let it dry for a few hours just in case and took it inside. While inside I noticed the armor had some sort of spray paint dust on it so I wiped it clean with a wet kitchen paper. After that I started working on attaching the fabric to the armor. The hot glue gun was my friend.

After hot gluing the front

Preparations for gluing the back

A part of the backside hot glued

I must say the backside was a bitch to glue. I burned my fingers more times than I remembered to count and I got hot glue strings everywhere and agjdsj. The backside isn't the prettiest but who cares because it will be against my body and unseen anyway... I let the hot glue dry and then I poked holes into those front things that had been covered in fabric.

le hole

With the hot glue dry I took my metallic golden paint and started painting on top of the glue to get the border thing Okita has on his armor.

Paint paint paint paint...

It took forever because I was being super careful and shit. I noticed the paint was pretty awesome because when you painted it on it seemed this dull super light gold sort-of-pankake-dough color but when it dried it started turning into a real gold color, cool!

When the paint had dried I made the edge border around the armor's upper part with hot glue.

Glue glue glue glue...

... and paint paint paint paint some more.

The paint took some time to dry completely so meanwhile I watched some Digimon Adventure to make the waiting time go by faster. I'm watching the first season for nostalgic reasons, ah. <3 And besides as a kid I never saw all episodes anyway...

When the golden paint finally had dried I just had to put on the ties and call it done!

Tadaah!

It's not 100% accurate but fair enough, neh? ;) You'll get to see it worn and in action soon enough because I will do an Okita preview before Skecon!

A plastic hell

Remember how I back in 6th April started working on Masamune's leg armors? Well, I've been slowly working on them over the last few month and now I figured I'll put all the rest of the progress in a single long follow-up post. Here goes!

Way back on 5th April I continued the leg armor work by drawing a pattern for the knee cap part of the armor. I had to make a few versions before I came up with one that seemed right. The early ones had a dent at the middle but I scrapped that idea on the final version.

The final pattern version

 With the pattern at hand I took the polystyrene and cut out two pieces...

... and then came the heat gun treatment to shape the plastic.

After having shaped the knee parts of the armor I took one of the leg pieces and tried the fit against it. I had to go reshape the knee parts a few times to get them to fit as well as possible and without leaving "empty space" where the bent parts of both pieces met.

Testing the fit

Over 5th April and the two following days I was struggling with trying to find some method to glue the pieces together. I tried several different adhesives that we had available at mom's place on scrap pieces but nothing seemed to work and the despair-&-frustration meter was rising fast.

I tried hot glue, construction adhesive (?), pvc glue, epoxy resin and allround glue... and nothing worked. Fuck. :)

I kind of left it at this point for some days in frustration to try and come up with what to try now. On 23rd April I was feeling like going through hell again trying once more. I thought that if I gave the surface a rough treatment with some sand paper maybe it would maybe make a difference at how well the glues would stick. But of course before trying any glues on the actual armor parts. I had to draw some marks where the glue would sit and thus also where to sand.

Edges marked...

... and sanded.

On the same day my stepdad had been cool and bought some kind of glue that claimed it would stick to polystyrene.

Equipped with a glue that gave me hope I decided to tackle the damn plastic again, but this time trying the glue on the actual armor parts and not just scrap pieces as before. So with a helping hand from stepdad we glued the knee caps to the armor pieces at the marked lines and secured them to dry over the night.

You better be stuck together when I return... *glare*

About 24 hours later on the next day (24th April) I returned to check if the glue had done what it claimed it could and low and behold, the pieces didn't separate even after I tried to bend and put some pressure on them!

I could have been happy at this point.. but colored by the reminder of earlier gluing failures and some justified iffyness I decided to be extra-super-duper safe and reinforce the part that attaches the knee cap to the leg armor with some rivets. So on 26th April I marked where to drill the armors.

Holes marked with a pencil. There's 4 holes.

After drilling.

Actually my stepdad did this next part for me, namely inserting the rivets with a hand riveting tool.

Hand riveting tool

First we tried a rivet on scrap pieces just to check that it worked, which it did. Then we put rivets on the actual armor.

Front with rivets (surface paint cracked a bit)

Backside

I quickly realized the backside of the rivets would probably get really uncomfortable because they stick out and well, having them pressing against my legs all day in cosplay can't be a very pleasant experience. Stepdad then showed it was possible to cut off parts of the backside of the rivets if you were careful not to hit that thing in the center. He went ahead and trimmed the rivet backsides before I even knew of it some hours later while I was in my former room (this was while I still lived at mom's place) doing something else; he did it without me knowing. xD

A "trimmed" rivet backside

A few days later, on 29th April, I noticed that the paint didn't stick that well to the polystyrene. It was possible to peel it off with your nails or something semi-sharp.

Oh crap...

Again I thought that if I sanded the surface the paint would stick on better. I used some sanding paper with a very high number, super fine grit.

Preparations - sanding papers, armors and a chunk of finnfoam to wrap sanding paper around

Front leg armors front sanded

Back leg armors front sanded

I left them in this sorry state for some time because I moved away from mom's place into my own apartment and thus couldn't work on my Masamune cosplay as often as before. But on 12th May I returned to work a few hours!

Because of the earlier sanding there was dust of the spray spread over the armor surfaces and so, to clean it, I had to use white spirit.

I just used some tissue paper, put some white spirit on it and wiped the surfaces clean of dust. After that I let them dry for around 2 hours outside and then returned to recoat the fronts of all the armor pieces.

Newly sprayed coat of paint on top front sides

I left them to dry over the night because I had to leave for my apartment. It took me until 8th June before I got another chance to work on these again and when I returned mom had told me some things that sounded weird and bad. "The color is flaking everywhere." I had heard and I wasn't sure what she meant until I got there and saw the armor pieces. The fronts which I had treated and recoated earlier were as fine as ever but the backsides -which I had left completely untreated after sanding the surfaces- had pooed black flakes basically everywhere and even the slightest touch let lose a dark cloud of them!

Maximum flaking. Fuck. :)

I tried softly rubbing my finger against the flaking surface and...

... almost all of the (sanded) spray coat fell right off!

And on all the untreated back sides to boot!

Nothing to do but to let lose a few curse words mentally and give the back the same white spirit and recoat treatment I had given the front sides quite long ago.

On 24th June I decided to try them on and crossed my fingers but somehow I had a feeling it wouldn't go well. Guess if I was right? :DD
Before starting I cut out lengths of white cotton ribbon and sat down on the floor and started tying the armors on one of my legs. I started with the backside armor and at first everything seemed alright but when I started with the front armor I noticed things started screwing up. First of the armors wouldn't stay where intended and they would constantly turn to either the right or left and, secondly, the lower ties would slide down if I moved and sometimes if I didn't -.- and thus the armor would "pop out". I guess it slides down because the surface is kinda... plasticy/slippery (there's no grip) and because feet get narrower closer to the ankle. Frustrating to say the least.

Testing. Notice backside armor has "popped out" from the lower tie..

I also noticed that the backside armor had flaked some paint off in strips at the high tension bending point, the middle.

The front armor didn't flake though. I'm pretty annoyed because this means I likely have to come up with something else for the armor and I'm running short on time. I can probably still use the front piece but I would have to replace the backside armors with something with a rougher/uneven/non-slippery surface so that they won't slide around and shit. I guess I will try mutilating a roll mat...