Making "Iron" Armour Pieces

So today I decided to start work on this for Animaga in August:


 


I've only ever made leather armour before, so working on something that had to look like metal was definitely going to be something new, and I could only use the materials I had lying around the house... These are the steps I used to make it! The pictures are of the Pauldrons.

Materials:

• Cardboard sheets (could use normal cardboard but this was easier to manipulate)
• Aluminum foil
• PVA glue (a lot of it, dries clear)
• Black acrylic paint
• Paint brushes
• Scissors

Method:

1. PLAN

You don't want to go through cutting all the cardboard and having it not fit the shape you want!

Draw a diagram or print off a photo to work off.

Cut some draft shapes out of paper and stick them together with tape. Once you're happy with the shapes, take the tape off and use these as templates.

2. CUT

Now you need to cut the shapes out of the cardboard. I used thin sheets and so had to make everything with two layers so it wasn't too weak. If you have also done two layers, glue these together with PVA.

3. SHINY

So this part was new to me. I brushed PVA all over the main surface of each piece. I didn't do the back but I suppose you could if you wanted to, it just might get messy with the foil crinkling up. 

I then took a strip of aluminum foil to approximately the size of the piece and cut it with sharp scissors. 

DO NOT rip on the serrated edge, this will crinkle the foil way too much and you could be left with a messy ripped edge.

Carefully lower this onto the glued section of the piece and working from the center outwards, smooth it down onto the glue properly. Fold over the edges, let it sit for a bit, and then tape or glue these edges down.

If you want, you could create bumps and designs with glue (preferibly hot glue) before putting the foil on. This way when you smooth the foil down you will create patterns rising out of the general surface.

4. EFFECT

So I had my brush from the glue sitting in a jar of water. I used this same water while coating the surface in a watery/thin layer of black paint to roughen up the look and make it seem more realistic. This made the surface a little more cloudy while it was drying and seemed to help the paint stick. Maybe I'm wrong and it did nothing, but that's what I did. 

If you etch designs into the foil and then paint over them they should stand out better too. 

Let it completely dry and don't get water on it.

5. PROTECTION

I finally did a top coat of the PVA glue to protect and strengthen the foil surface and hopefully keep it slightly waterproof. I'm sure there are better products for doing this, but PVA was all I had on me at the time. 

6. PUTTING IT ALL TOGETHER

Now you can put all the pieces together because the metal effect is done!

I hope this helps!

- Michelle