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old scale armor set
How to make Helm



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

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 50cm
→5mm thick 100cm X 60cm
-Plastic sheets 0.5mm thick 4piece
-Synthetic leather 100cm X 20cm
-Cloth 100cm X 50cm
-Fur 100cm X 100cm
-Clear platic ball 1piece
-Liquid instant glue 5pieces
-Polyester putty 100g
-Hot melt(glue gun) 20piece(When you use a Air duster for cooling, it's convenient))
-Wire 50cm
-Aluminum stick 1piece
-Gardening stick made by glass fiber 1piece
-Velcro 40cm
-Wig 1piece

[Painting materials]
1.When a undercoat is Gesso
-Gesso 100ml
-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) 200ml
-lacquer thinner 200ml
-Paintbrush 1piece
-Paper cup, bowl etc 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*

*The paiting area is written in the package, refer it. Details are here.

Materials cost
6000Yen (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
-Paint tools, such as a paintbrush
-Drill or Pinvice
-Pliers
-Sewing machine
-Sewing tools
-Tools for processing plastic sheets(sandpaper etc)

Convenient tools when you have
-Art knife PRO
-Instant glue Accelerator
This spary can harden Instant glue instantly. Details are here.
←100ml ←180ml ←420ml

Work time
80Hours

Spec
-

Template
I threw away the Templates, so I can't upload.

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.
<-I'm using this 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 Templates from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).
When you make Templates of the head, use a mannequin head.
When you want to know detailed tutorial of making Templates, browse this page.







Make Templates from Tracing paper.



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


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

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.

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


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


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


Instant 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 movie.

Instant 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 instant glue
I use general liquid Instant glue.


Case of sticking except instant glue.
"Bond G17"(one of liqud glue in Japan) can glue too. It's can glue narrow surfaces too.
But it's take time.
Moreover, when you use Thinned "Bond G17"(one of liqud glue in Japan) as a undercoat,
glued surfaces may melt.
(If you use Gesso, there is no problem.)

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


Cut out 2mm or 1.5mm thick EVA foam.


【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】


Cut out 2mm or 1.5mm thick EVA foam.


Glue with a Liquid instant glue.


Cut out 2mm or 1.5mm thick EVA foam.


Glue with a Liquid instant glue.


Glue with a Liquid instant glue.


Cut out 2mm or 1.5mm thick EVA foam.


Cut out 2mm or 1.5mm thick EVA foam.


Cut out 2mm or 1.5mm thick EVA foam.


Cut out 2mm or 1.5mm thick EVA foam.


Glue with a Liquid instant glue.


Cut out 2mm or 1.5mm thick EVA foam.


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



Glue with a Liquid instant glue.


Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid instant glue.


Paste together parts cut out from 2mm or 1.5mm thick EVA foam with a Liquid instant glue.


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


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


Paste together parts cut out from 2mm or 1.5mm thick EVA foam with a Liquid instant glue.


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


Draw patterns with a Hot melt(glue gun).



Use a clear plastic ball.


Make hole with a Pinvice or Prick punch etc.



Paste the half.
Glue with a Hot melt(glue gun).
Cut out 10mm thick EVA foam.
Glue with a Liquid instant glue.


【10mm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


【10mm厚COSボード】


Paste the left half. Glue with a Liquid instant glue.


Paste together parts cut out from 2mm or 1.5mm thick EVA foam with a Liquid instant glue.


Cut out 10mm thick EVA foam.
Glue with a Liquid instant glue.


Paste inside. Glue with a Hot melt(glue gun).


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.

【Demerit】
-It's easy to come off than Thinned "Bond G17"(one of liqud glue in Japan). (Moving parts in particular)
-It can't use for PVC pipe or plastic sheets.

【Recommendation】
-Weapons
-Armors without a moving part.

【Undercoat】
Gesso or Black Gesso
or

【Paint】
Lacquer Spray or Bottle lacquer paint or acrylic paint
or
-------------------------------------------------------------------------------------------
2.Thinned "Bond G17"(one of liqud glue in Japan)
This is difficult.

【Merit】
-It's sold in D.I.Y shops.
-It'st hard to peel off.
-It can use for PVC pipe or plastic sheets.

【Demerit】
-You must thin it.
-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.

【Recommendation】
-All props
(Props with a moving part in particular)

【Tutorial video】


【Undercoat】
"Bond G17"(one of liqud glue in Japan) thined with lacquer thinner
-for big things -for small things

【Paint】
Lacquer Spray or Bottle lacquer paint

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

I use Thinned "Bond G17"(one of liqud glue in Japan) in this tutorial.
But I recommend Gesso for begginers.


Paint "Bond G17"(one of liqud glue in Japan) thined with lacquer thinner three or four times.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.
(It will char in seconds.)
Dry it about 2 ~ 6 hours.
Paint black color as undercoat color with Lacquer Spray.


Paint gold Bottle lacquer paint by Drybrush painting.


Drybrush painting is easy, you can do it with a paint brush.
Read here or watch this video.


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.


Painting was completed.


Make a strong core by combining a Gardening stick made by glass fiber and a Aluminum stick.
Cut it into appropriate length with a Pliers.


Use Gardening stick made by glass fiber as core.
Cut a Gardening stick made by glass fiber into appropriate length.
When you use a Fret saw or a Freeway coping saw, you can cut it easily and neatly.
You can cut also Pliers, nippers, diamond files.



In some cases, adjust the thickness by peeling the skin of Gardening stick made by glass fiber with a Box cutter.
Paint "Bond G17"(one of liqud glue in Japan) on it, and insert to the Aluminum stick.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.



Make ball part from a cork ball, a wood ball, a beads.
Make hole with drill.


Draw patterns with a Hot melt(glue gun).


Paste Aluminum stick. Glue with a Hot melt(glue gun).


Cut out 0.5mm thick Plastic sheets.
Make hole with a Pinvice or Prick punch etc.



Glue with a Liquid instant glue.


Heap Polyester putty.
Wait untile hardening.

←120g ←1kg

Form by shaving with a Box cutter.
Polish with Sand paper of around 400grit.


Form by shaving with a Box cutter.
Polish with Sand paper of around 400grit.


Polishing was completed.


Mark pattern by penn.


Shave with Leutor.


Use a wire.
Use it as a core.
Bend with hands and Pliers.


Heap Polyester putty.


Heap Polyester putty.


Wait untile hardening.


Polish with Sand paper of around 400grit.


Thin lacquer putty with lacquer thinner.



Paint lacquer putty thined lacquer thinner on hollows and cracks.


Polish with Sand paper of around 400grit.
Paste to stick part.
Glue with a Liquid instant glue.


Stick Masking tape on the point you don't want to paint.



Spray Surface Primer.
Cracks and hollows stand out after drying.
Repeat above process until the surface becomes flat.



Paint black color as undercoat color with Lacquer Spray.


Paint gold Bottle lacquer paint by Drybrush painting.


Cut a wig.


Glue with a Hot melt(glue gun).


Glue with a Hot melt(glue gun).


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.



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.


Glueing was completed.


Make flaps.
Way of making is similar to cloths.


Way of making is similar to cloths.


Way of making is similar to cloths.


Make chin codes. Sew with a sewing machine.


Paste Velcro as spacer inside.
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.



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Stick part can take off.


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