From Workshop
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To Arms! (Two Arms?)
The forearms really jump out as being one of the things different between the AotC and CW armor. The elbow pads are attached, and the shape is completely different. I chose these as the first piece to make for myself.
The Method To My Madness
I didn't want to have to sculpt the pieces, mold them, then pour a positive to vacuum form over. So, I went with something that could take the heat and pressure: MDF!
Forearms
I started out by tracing my arm on a sheet of craft paper. I did one of the top and one of the side, keeping it as accurate as I could. I then outlined that with how I wanted the armor to look. I extended the wrist a couple of inches to allow for longer arms than mine while I was at it.
Once I got the armor drawn out, I divided it into 3/4" slices (the thickness of the MDF) and down the middle (the separation between the top and bottom shell). Once the pieces were cut, I glued them together with wood glue, sanded them as smooth as possible, then broke out the Bondo.
 Sketch to show me the pieces I needed |
 Rough cut MDF |
 Sanded smooth |
 Coated in Bondo |
 Rough cut elbow |
 Elbow smoothed out |
 Vacuum Formed |
 Painted and ready to troop |
Biceps
The biceps aren't really very exciting. They are just cylinders with an indent for the elbow armor. I didn't even take pictures.
Handplates
Same as the biceps, I carved the handplates out of single pieces of MDF in about 10 minutes on the big stationary belt sander. These are version 2. The first ones I wasn't very happy with.
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Shoulders
We recycled scout trooper shoulders. Trimmed differently they work great and saved a sculpt.
