I then drew up new schematics of everything I wanted to make. Then went over to Lowe’s and picked up some material. With this armour I was going for the Medium (Jango) armour type with shins, thighs, and lace covers (which hide your shoelaces). Today I used Mandomaker to through together my concept design with a color scheme.
I then used 3″ PVC pipe to make the knee armour using this long winded 9 part tutorial on youtube: https://www.youtube.com/watch?v=m2e-evq2jNw
I will not be using darts in my knee armour so it simply protects my knees in combat. I also cut out and rolled (fold the metal back on itself to form a blunt edge instead of a razor edge) the sheet metal into shoulder armour.
The shoulder armour will be attached to the flight suit with the same method I plan to attach the chest and back armour to the flak vest (industrial velcro). I then started cutting out the sheet metal (using a cutting wheel on my grinder) for more of the armour pieces (next paycheck will be the rest of the armour pieces).
I laid my sheet metal pieces out and then started to roll the edges back on everything to avoid cutting myself later.
I am extremely satisfied with the back plate. It came together quite nicely.
I painted my back plate the same colour orange:
The next day after work I started the hunter green accents around the edges of my armour. It kind of makes it pop better and will transition well to my green flak vest whenever I redo that. I also cut out the Mandalorian symbol and made the shadow effect on the back plate (see below).
The concept design was created during the week (see quick sketch below).
I had a slow day at work on Friday and was able to get off a few hours early. I met up with my friend and we started working on his armour (schematic colors of army green and blood red). I got some elastic and Velcro to use for attaching. First thing I used the elastic on was the knee armour plates.
I also worked on my boot armoured lace covers with some schematics drawings I had done earlier in the week.
I also helped my friend make the basic cutouts of the 4″ PVC pipe for this own gauntlets. Limited on my tools of the trade so I used a grinder and a circular saw to cut the pieces in half.
Below is an image of what I have so far; with the steady merge of Sintra to metal armour in progress.