OK, I am working my way through the rest of this write-up! This time, it's all about legs!
From where I left off, I decided to get moving on the legs in an effort to get all the major armor pieces assembled and pre-painted.
The thighs and shins were cut out, heat shaped and assembled. Once they were together, the details were added and all the decorative lines cut in using the same process as the rest of the pieces.
The backs of the shins were made as soft pieces to match the torso base and some of the other areas that will detail the suit. They were made by backing the metallic fabric with headliner foam and then adding 'straps' made of 2mm craft foam covered with metallic and sewn down. These pieces will fit over existing boots and the shin armor will fit over them.
This is basically what the legs will look like when together.
The next step was to PlastiDip and base paint the pieces.
The thighs were closed on the inside with wide straps. These straps were made by lining the silver material with headliner foam, binding the edges and then adding details made out of silver fabric and 2mm craft foam - just like the backs of the shins. These pieces were then contact cemented into the thighs.
To hold the thighs up, I created a wide elastic belt with clips on the sides. The belt rides up very high on the waist and is covered by the torso piece. When the thighs are clipped on, they stay at the right height and have quite a bit of movement.
Once the thighs were done, I needed to build the feet. I used a base pair of boots and created a tape pattern of them from the ankle down. This pattern served as a base to create both the templates for the foam pieces as well as the foundation pieces that would cover the boots.
Since I wanted to be able to use these boots for other projects, I didn't want to have anything permanently attached to them.
I made the foundation piece first out of silver fabric backed with headliner foam. All of the craft foam pieces of the foot will be attached to this piece and it will simply slip over the boot like a spat.
Next, using the pattern, I made paper templates for the foam pieces, tested them, trimmed and adjusted until they fit. Here are the finished foam pieces, 3 for each foot - toe, upper and heel.
The pieces were coated with Plasti Dip, contact cemented to the foundation piece and then base coated with silver paint.
The next stage of the legs was to attach the shins to the calves. The soft calf piece was contact cemented to the shins on the outside and a series of snaps added to the inseam area so that they could be opened and closed.
All of the pieces were then airbrushed and detail painted by hand. Here are the boots fully assembled.
And here is a test fit of the entire leg together.
Next up - hands, cape and finishing up. Stay tuned!