Chloe Zhang
Whether it's for costumes, conventions, or role-playing, creating fantasy armor from plastic is a fun DIY project. The process involves using plastic sheets or recycled plastic chemical barrels, which are cut, heated, and shaped to form the desired armor design. Different types of plastic, such as HDPE, ABS, polyurethane styrene, and Wonderflex, can be used depending on availability and the desired characteristics of the armor. With the right tools and techniques, plastic can be formed into durable and aesthetically pleasing armor, providing a creative and affordable option for enthusiasts.
| Characteristics | Values |
|---|---|
| Materials | HDPE plastic barrels, ABS plastic sheets, polyurethane styrene, Deco Art, Wonderflex, Friendly Plastic, Worbla |
| Tools | T-shirt, white poster-board card stock, Sharpie, electric jigsaw, serrated steak knife, heat gun, dremel, sander, paintbrush, varnish, acrylic paint, primer filler, gloss, clear coat |
| Techniques | Sketching and cutting template, tracing and cutting plastic, heating and forming plastic, sanding and cleaning, painting and coating |
| Considerations | Safety, durability, cost, ease of access to materials, desired shape and contour, left and right sides, interior and exterior surfaces |
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What You'll Learn
Sketch your design on card stock
When creating fantasy armour from plastic, it is important to sketch out your design before cutting and shaping the plastic. Using large white poster-board card stock, lay one of your T-shirts on top and begin sketching a basic design, including generous 'excess' tails that can be trimmed away later. This will serve as your template. It is important to use white card stock as it allows you to leave pencil notes and remarks directly on the card, such as "front" or "back", "inside/outside", and specific details like "add 1 inch here" or "trim this". These notes will guide you during the cutting and shaping process.
Take body measurements to ensure that your armour will fit the wearer properly. You can refer to sources such as Techniques Of Medieval Armour Reproduction: The 14th Century by Brian Price for guidance on taking accurate measurements. Additionally, consider the desired shape and contour of the armour, especially when forming the pieces over curved body parts like the shoulders. You want the armour to have a comfortable and secure fit.
During the sketching process, feel free to experiment with loose sketches and tests until you find a design that you are happy with. You can find inspiration from various sources, such as medieval armour history, fantasy books and novels, Pinterest boards, or YouTube channels dedicated to armour creation and maintenance. For example, Knyght Errant's YouTube channel and website offer a wealth of information and inspiration for those interested in medieval and fantasy armour.
Once you are satisfied with your sketch, cut out the template with scissors and save it for reuse. You can then lay this template onto the plastic barrel lengthwise to help form the general shape of the armour. Trace the design onto the barrel using a marker, and cut out two of these templates for the front and back of your armour.
Remember, the sketching process is a crucial step in designing your fantasy armour. It allows you to plan and refine your ideas before committing to cutting and shaping the plastic. Take your time, seek inspiration, and make any necessary adjustments to your design before moving on to the next steps of the armour-building process.
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Trace and cut out plastic
When creating fantasy armour from plastic, tracing and cutting out the plastic is a crucial step. Here is a detailed guide on how to do it:
Tracing the Design
Start by laying out your template onto the plastic barrel lengthwise. This will help you form the general shape of the armour. You can use a T-shirt and place it on large white poster-board card stock to create your template. Trace the design onto the barrel using a marker, making sure to trace two templates for the front and back of your armour. Include generous 'excess' tails that will be trimmed away later.
Cutting the Plastic
There are several ways to cut through plastic, depending on its thickness and type. For thin plastic, such as a water bottle, you can use scissors or a small knife. For thicker plastic, a saw is usually required. Here are some specific methods:
- Jigsaw: Hold the plastic firmly or clamp it to a table. Squeeze the trigger to start the blade moving before touching it to the plastic. Use firm pressure to push the blade through the plastic.
- Table Saw: When using a table saw, be aware that the heated blade may melt the plastic. Use a non-melt blade with evenly spaced, close-together teeth to avoid this issue.
- Fine-Toothed Saw: This type of saw provides the cleanest cuts. It is better than a wood-cutting saw, which will rip the plastic to shreds.
- String: Wrap a long piece of string or sewing thread around your hands and then around the section you want to cut. Pull the string back and forth rapidly with medium force to generate heat and friction, allowing you to snap off the plastic.
- Drilling and Knife: Drill a series of small holes in the plastic you want to remove, then use a hobby knife to slice through the plastic. This method helps maintain the integrity of the plastic while allowing for precise cutting.
Remember to work carefully and wear appropriate protective gear when cutting plastic to avoid any injuries.
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Heat and mould plastic
To form plastic for fantasy armour, you can use a product called Wonderflex, which is a thin plastic sheet with a layer of gauze-like fabric embedded into it. Wonderflex becomes malleable when heated and can be shaped with your fingers or over a mould.
To make a mould, you can use a balloon and strips of newspaper. Wet the newspaper strips with wallpaper paste and shape them around the balloon. Apply several layers and let them dry, then varnish the mould to make it strong and durable. You can also use a plastic bowl or another round object if you want a ready-made mould.
Once you have your mould, you can cut off a large piece of Wonderflex and heat it with a blow dryer, a heat gun, or a hair dryer on high heat and low fan speed. You can then shape the heated Wonderflex around your mould. Alternatively, you can use scraps of Wonderflex, heat them up, and press them into the interior of your mould to cover up any seams or edges.
Another option for creating fantasy armour is to use recycled plastic chemical barrels. You can use a 55-gallon HDPE ("high-density polyethylene") plastic barrel, which is the type often used as rainwater collection barrels. First, thoroughly rinse the barrel, especially if it previously contained industrial-grade chemicals. Then, trace your design onto the barrel using a marker, and cut out your template using a portable electric jigsaw. You can then heat and form the plastic using a propane torch, but be sure to work outdoors as HDPE plastic emits noxious fumes when superheated. You can also use a heat gun or hair dryer, but these may be less effective for larger pieces of plastic.
After forming your armour, you can paint it with acrylic paints or use permanent markers. You can also spray on a coat of primer to help with adhesion, and then varnish it to prevent flaking.
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Harden plastic in cold water
To form plastic for fantasy armour, you can use a 55-gallon HDPE ("high-density polyethylene") plastic barrel. This type of plastic is often used as rainwater collection barrels and can be used to create rugged wearable chest armour.
To shape the plastic, you can use hot water to make it soft and malleable. Once it has cooled, it will harden into its new shape. You can speed up the hardening process by dipping it into cold water. This method can be used to create a general shape, angle, and contour for the armour.
- Begin by sketching a basic template design on a large white poster board card stock. This template will help you trace the design onto the barrel.
- Using a portable electric jigsaw, cut out two templates from the barrel, one for the front and one for the back of your armour.
- Gently heat the plastic until it is bendable, then form it into the desired shape for your armour.
- Slowly immerse the plastic into cold water. The plastic will harden immediately, often with an audible gurgle of steam.
- You can now paint your armour with spray paint or any colour of your choice.
It is important to note that this process is not recommended for creating functional armour for combat situations. Plastic armour is more suitable for costumes, science fiction/fantasy conventions, or role-playing. For functional armour, you may need to explore other materials and methods.
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Sand, prime, and paint
Sanding, priming, and painting are crucial steps in creating a smooth and aesthetically pleasing finish for your fantasy armor. Here is a detailed guide to help you through the process:
Sanding:
Before you begin, ensure your armor is clean and free of any debris or residue. Use a fine-grit sandpaper or sanding blocks to smooth out any imperfections, high spots, or low spots on the plastic surface. Pay close attention to the edges and curves of the armor, as these areas may require more sanding to achieve a seamless finish. Take your time with this step, as it is important for creating a uniform surface for the primer and paint to adhere to.
Priming:
Primer serves as a base coat for your paint and helps it adhere better to the plastic surface. Choose a primer suitable for plastic surfaces, such as a latex primer or a filler primer. Brush or spray the primer onto the armor, ensuring even coverage. Apply multiple thin coats if needed, allowing each coat to dry before applying the next. If you notice any defects or imperfections after priming, you may need to repeat the process of sanding, filling, and priming until you achieve a smooth finish.
Painting:
Once you are satisfied with the smoothness of your armor after sanding and priming, it's time to paint! Choose a paint suitable for plastic surfaces, such as spray paint designed for plastic or a paint specifically meant for fantasy armor. Consider the desired color and finish, whether it's a matte or gloss look. Apply light coats of paint, allowing each coat to dry before adding another. It's important to work in a well-ventilated area or outdoors when painting to ensure the paint dries properly and there are no strong odors.
Additionally, consider using a clear coat over your paint to enhance the finish and hide any minor imperfections. A clear coat can also protect the paint and ensure the longevity of your fantasy armor. Remember to follow the specific instructions provided by the manufacturers of the primer and paint you choose, as they may have unique application techniques or curing requirements.
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Frequently asked questions
You can use recycled plastic chemical barrels, preferably made of HDPE (high-density polyethylene). You can also use materials such as polyurethane styrene, Wonderflex, Friendly Plastic, or Worbla Deco Art.
Begin by laying one of your T-shirts on a large white poster board card stock. Then, sketch a basic design, including generous 'excess' tails that can be trimmed later. Cut this template and save it for reuse.
Place the template onto the barrel lengthwise and trace the design using a marker. Cut out two of these templates for the front and back of your armor using a portable electric jigsaw.
Using a heat gun, gently heat the plastic until it becomes bendable. Then, slowly immerse the plastic in cold water, and it will harden immediately. You can also use a product like Wonderflex, which becomes malleable when heated and can be shaped with your fingers or over a mold.
First, clean up the edges using a sanding bit. Then, apply a primer, followed by your desired paint color, and finish with a clear coat. You can also coat the interior with varnish to add durability.
