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How to make Japanese armors


Materials
[Materials for making templates]
-Drawing paper 10sheets
-"Kousakuyousi"(one of hard paper in Japan) 5sheets
-Scotch tape(Sellotape) 3pieces
-Packaging tape(parcel tape) 1piece

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 60cm
→5mm thick 100cm X 60cm
-Synthetic leather 100cm X 40cm
-"Bond G17"(one of liqud glue in Japan) 100ml
-Liquid super glue 3pieces
-Hot melt(glue gun) 10pieces (When you use a Air duster for cooling, it's convenient)
-Safety pin 4pieces
-hook for handicrafts 2pieces
-Red cord(for body) 17m
-White cord(for body and shoulder) 60m
-Blue cord(for waist) 48m

[Painting materials]
1.When a undercoat is Gesso
-Gesso 150ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint proper quantity*

2.When a undercoat is Thinned "Bond G17"(one of liqud glue in Japan)
-"Bond G17"(one of liqud glue in Japan) 300ml
-lacquer thinner 300ml
-Paintbrush 1piece
-Paper cup, bowl etc 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*

Materials cost
4000Yen (about 100Yen = 1dollar)

Tools
-Writing implement(Pencil,eraser,ballpoint,Magic Marker,ruler)
-Scissors
-Box cutter(Use also a "Pro blade" and a "Blade breaker")
-Cutting mat
-Hot melt(glue gun)
-Lighter
-Soldering iron and soldering iron stand
-Masking tape 1piece
-Paint tools, such as a paintbrush
-Pinvice or Prick punch etc
-Sewing machine
-Sewing tools

Convenient tools when you have
-Art knife PRO
-Super glue Accelerator

Work time
20hours

Spec
-

Template

PDF format(A4 size)
Body Click
Waist Click
Shoulder Click

-If you print on browser, it may not be full scale. You should save the file on your PC, then print the file.
-Print it with Adobe Reader(free ware).
-After printing, it becomes easy to use by sticking it on Drawing paper with spray glue.
-Size:Free size
-Mentions of "x1","x2" etc are the numbers of sheets.
(If you need both arms or both legs etc, cut the number of double.)
-Mentions of "2mm" , "5mm" etc are thickness of EVA foam.

Body Completion drawing


Waist Completion drawing


Shoulder Completion drawing


Attention in the work
-When you uses a thing including the thinner(Bond, lacquer thinner etc) or spray, make good ventilation.
And wear a gas mask.


-When you toast mterials etc, make good ventilation.
And don't breathe smoke, don't put smoke in your eyes.

-When you dig mterials etc with Soldering iron, make good ventilation.
And don't breathe in smoke, don't put smoke in your eyes.

-Don't use fire near the things which are easy to burn such as paint, thinner etc.

-When you finished using tools, pull an outlet.

-Read labels of materials and tools, and understand how to use.

How to make
Make a body armor.
Make Templates from Drawing paper.
When you want to know detailed tutorial of making Templates, browse this page.



Repeat cutting and pasting.
Templates was completed.


Make holes threaded cord.
Make hole with a Punch.


Use 5mm thick EVA foam.
Make holes on the patterns of the Templates. Mark them with a pen.


**********************************************************************

EVA foam is a soft material.
You can process it easily.
Another name is EVA board, EVA zote, Craft foam etc.
I usually use one called "Lion board".
"Lion board" is sold only in Japan.

Watch video.

**********************************************************************


【5mm厚ライオンボード(別名:リアラボード)】
リアラボードという商品名ですがこれが俗に言うライオンボードです。


楽天なら


【5mm厚COSボード】


**********************************************************************

Use a sharp blade. For example, "Pro Blade".
This is so sharp.
←10枚入り ←50枚入りお得パック

When you cut, put EVA foam on Cutting mat.
Don't cut in the air, while holding by hand.
Break a b blade frequentry, if you feel sharpness of using blade became bad.
If you want to do work more speedy, use "Running fire box cutter","Blade breaker".
"Running fire box cutter" can have 6 pieces blade inside.
"Blade breaker" can break easy and speedy.


Use Art knife PRO for small ornaments etc.

**********************************************************************


Mark with a pen.


Marking was completed.


Cut out 5mm thick EVA foam.
Make hole with a Soldering iron.(Don't breathe in the smoke and don't put in eyes)



Glue with a Liquid super glue.
When you use a Super glue Accelerator, Hardening speed becomes fast.
(Smoke may be generated. Don't breathe in the smoke and don't put in eyes.)


**********************************************************************


Super glue can glue a large surfaces easily.
But it can't glue a small surface such as this photo well


Then you should use a following spray.
I always use this.
Watch video.


Super glue accelerator
This can glue surfaces in several seconds.
When you use 100ml, you can make a armorset or about three weapons.
←100ml ←180ml ←420ml

About super glue
I use general liquid super glue.

**********************************************************************


Cut 5mm thick EVA foam thin. Shave the corners.


Glue with a Liquid super glue.
Remove the corner by toasting with a Lighter.(Don't breathe in the smoke and don't put in eyes)

←ガス充填式ライターとガスボンベを使うとお得

Make belts.
Cut out 2mm or 1.5mm thick EVA foam.
Glue Synthetic leather with "Bond G17"(one of liqud glue in Japan). Details are here.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.



【1.5mm厚ライオンボード(別名:リアラボード)】
リアラボードという商品名ですがこれが俗に言うライオンボードです。


楽天なら


【1.5mm厚COSボード】


Glueing was completed.


Stick to the body.
Glue with a Hot melt(glue gun).


Glue Velcro with "Bond G17"(one of liqud glue in Japan) or a Hot melt(glue gun). Detailes are here.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.



Begin painting.
At first, paint a undercoat on EVA foam.
The effects are as follows.

-Color becomes well.
-It becomes hard to come off.
-Gloss comes out well.
-You can save quantity of the paint.

There are two methods.
-------------------------------------------------------------------------------------------
1.Gesso
This is easy.

【Merit】
-It's usable just to paint with a paint brush.
-Gesso don't contain thinner, then you can use it in the room.
-You can use also Acrylic paint.
-There are several colors one, white black etc.

【Demerit】
-It's easy to come off than Thinned "Bond G17"(one of liqud glue in Japan).
 Then, use this for weapons and armors without moving parts.
-The gross is smaller than Thinned "Bond G17"(one of liqud glue in Japan).

【Commodities page】
Gesso or Black Gesso
or

【Paint】
Lacquer Spray or Bottle lacquer paint or acrylic paint
or
-------------------------------------------------------------------------------------------
2."Bond G17"(one of liqud glue in Japan)
This is difficult, however it's almighty.

【Merit】
-It'st hard to peel off.
-It can use for PVC pipe or plastic sheets.

【Demerit】
-"Bond G17" is japanese commodity.
 Then you can't get it easily.
 Please use others. For example, you can substitute wood glue for it.
-You must thin it with lacquer thinner.
-It needs thinner, then you must work outdoors.
-It burns easily.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.
The parts will be charred in seconds.

【Tutorial video】


【Commodities page】
"Bond G17"(one of liqud glue in Japan) thined with lacquer thinner
-for big things -for small things
-------------------------------------------------------------------------------------------
-About paint
I use following paint.


You can use acrylic paint, when you use Gesso.

-------------------------------------------------------------------------------------------

I use Gesso in this tutorial.


Paint Gesso twice or three times with a brush.
Dry it about 2 ~ 6 hours.


Paint black with Lacquer Spray.


Paint gold of Bottle lacquer paint with a paint brush.


When you paint Bottle lacquer paint, use a paintbrush,silicon cup(Use as a paint plate. It can easy to peel paints after dry.),
panint stick, thinner.


Thread cord.
-Red cord 17m
-White cord 20m

Cut 1.5m for easy using.
Make a knot in the one side.
Sharpen another side.
Harden with Liquid super glue and sharpen.


Sharpen tips more with Box cutter.


If holes are closed by painting, insert thin article.
Make hole with a Pinvice or Prick punch etc.



Thread cord.


Thread cord.


Stretch cord over a thumb, and thread. Then it was finished neatly.


Paste the end with Liquid super glue in backside.
Moreover serve with Hot melt(glue gun).


Thread second cord.
Afterward, repetition.


Complete.


Make waist armor.
Make Templates from "Kousakuyousi"(one of hard paper in Japan).



Copy the edges of Templates on a material with a pen.
Cut out 2mm or 1.5mm thick EVA foam.


Glue with a Liquid super glue.


Glue Synthetic leather on the backside with a "Bond G17"(one of liqud glue in Japan) for reinforcement. Detailed process is here.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.


Remove the corner by toasting with a Lighter.(Don't breathe in the smoke and don't put in eyes)


Make hole with a Soldering iron.(Don't breathe in the smoke and don't put in eyes)
Draw patterns with a Hot melt(glue gun).


Paint.
Painting method is same as body armor.


Stick cords.
Glue with a Hot melt(glue gun).


Cut out cloth.
Sew with a sewing machine.


Temporal tack with Masking tape.



Try on.


Thread cord.
-Blue cord 48m


How to thread.


Threa in order of numbers.




















Tie at last in backside.


Tieing was finished.


Tieing was finished.


Complete.


Make waist armor.
Make Templates from "Kousakuyousi"(one of hard paper in Japan).


Copy the edges of Templates on a material with a pen.
Cut out 5mm thick EVA foam.


Glue with a Liquid super glue.


Copy the edges of Templates on a material with a pen.
Cut out 2mm or 1.5mm thick EVA foam.


Glue with a Liquid super glue.


Glueing was completed.


Make hole with a Soldering iron.(Don't breathe in the smoke and don't put in eyes)


Remove the corner by toasting with a Lighter.(Don't breathe in the smoke and don't put in eyes)


Draw patterns with a Hot melt(glue gun).


Paint.
Painting method is same as body armor.


Thread cord.
-White cord 40m












Make a cylinder.
Cut out 5mm thick EVA foam to belt form.
Paste together end and end with Liquid super glue.


Let wire pass to inner.
Paste the end of wire. Glue with a Hot melt(glue gun).


Cut out cloth.


Glue with a Hot melt(glue gun).


Attach a hook for handicrafts.
Glue with a Hot melt(glue gun).


Attach a hook for handicrafts.
Glue with a Hot melt(glue gun).


Stick the cylinder.
Glue with a Hot melt(glue gun).


Glue a Safety pin with a Hot melt(glue gun) for equiping.
(There is also a method that use Velcro. Details are here.)


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Visitor's works

アラキさん
月風魔の甲冑
こちらは「戦国甲冑のつくり方」のページを参考にしております。
甲冑を装着する為の「安全ピン」をグルーガンで接着する技術は本当に役に立ちました!
塗装はヘルメットと同じくジェッソを2度塗りした後、ジェルメディウムを塗り、ラッカーを使用しております。
甲冑が全身に及ぶため、かなり時間はかかりましたが、ギャクヨガさんのサイトには本当に勇気付けられたました!


NekochaQBさん
同田貫アーマー一式
いちおう完成しました。(兜のぞく)
制作にあたってはギャクヨガ師の作例を
参考にさせていただいております。


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