I didn't make mine using leather at first. I made them using the JediElfQueen foamie tutorial (
http://www.jedielfqueen.com/lotr/costumes/Boromir/vambraces/vambraces.htm) which is a really great method of recreating the leather tooling without actually learning to tool leather. :lol
My first attempts were pretty crude. Foamies for the tooling top part and upholstery vinyl for the back. The straps are vinyl and the buckle are off an old backpack I bought at an army surplus store.
After really looking at screengrabs from the movie and the kropserkel set I decided I wanted to remake mine more accurate but still try to avoid tooling leather or paying the $300 price tag for the KS.
I made some drawings, template out of paper, and then created some templates in Adobe Illustrator. Here's a mockup of the templates put together:
I feel it's a pretty accurate shape. If anyone wants to download them there's a zip of the AI files here:
http://dl.dropbox.com/u/2354750/Aragorn_Bracer_templates.zip
Eventually I went through like 3 prototypes before I made my final set. The tooled top was still made out of foamies but I perfected a better wash for the top that didn't turn out so shiny. The bottom layer was made out of black upholstery vinyl. I attempted to recreate the frenched edge on the kropserkel set by adding a layer of cheap suede underneath the foam that curled over and was stitched down. Giving the raised edge seen in the kropserkel bracers. Of course now, years later, I know that they did a frenched edge and now know how to actually do that. But I didn't then. The suede and foam was glued and saddle stitched to the bottom vinyl layer using waxed thread and a saddle needle from Tandy. The straps were made with excess suede that had a lot of gum tragacanth added and burnished smooth with a spoon back. Those were stitched to the bracers and the buckles using waxed thread.
The under bracers were cut using the same templates, although enlarged slightly. They are two layers of cognac upholstery vinyl hand stitched in a diamond pattern to give the quilting. Then an strip of the same material was added to finish the edges. Grommets and leather cord lace them up.
Sadly I think I may have lost all record of those final versions to a hard drive crash. But here's a pic of the costume about 3/4 done, you can kinda see the bracers:
The full costume is a duster from Museum Replicas Ltd, red shirt from Twin Roses Designs, a crappy fake suede costume jerkin with added braded leather ties, MRL Kingly Belt, black tights, costume boots, my braces, costume Ring of Barahir, Leaf of Lothlorien and Evenstar pendant, and a Fellowship cloak from eBay. Oh and that monstrosity that is Anduril.
Eventually I did way more work on the duster, heavy weathering with sand paper, sander, wire brush, dirt, fuller's earth, and shoe polish. I got some boots from Caboots that weren't all that great but I weathered the crap out of them. I added the Elven knife and the Anduril scabbard, though you can't really walk around with that sword sheathed. I think I eventually got the Strider sword when all the UC stuff was dirt cheap a few years back.
I'll look through some backup discs at home and maybe I can find the pics of the finished bracers. I'd really like to find them again.