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Forarm Armor tutorial

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whitmers (Shaye Whitmer)
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PostPosted: Fri Jun 27, 2014 2:45 pm    Post subject: Forarm Armor tutorial Reply with quote

I don't have any pics as I did mine last summer, but I do wish I had something like this easily available for when I started my build. As more people want to do generic jedi generals, this might help. You can see pics of how it turned out in my profile.

I used this base tutorial for mine, but I was also doing full arms and legs so I was pretty much making a clone trooper.

However, for just making the forarms, this should help.

you can get some great armor sets from (where I got mine)

or (

or make it out of worbla (much much more challenging)

So assuming you got yourselves the armor kit here are the steps.

step 1. trim your material down (this is the hardest part, I used something like these

step 2. once you have it trimmed, then tape the halves together with the tape on the outside (i recommended clear packing tape)

Step 3. cut fiberglass tape (from an autobody store) and trim it to the desired length. This will go along the inside seam.

step 4. slather inside seam with epoxy (from autobody store or home depot) then lay down the fiber glass tape and press it down firmly so that the epoxy squishes through the tape, and then layer more epoxy on top of it/

step 5. let it cure. then take the inner tape off. It should come off in one piece the epoxy doesn't adhere to it well if there are gaps.

Now the fun part begins:

I would get a respirator (not necessary.... but a good idea, or make sure you are doing this part outside)

Step 6. Sand the seam area down with 120 grit sandpaper so that the gap filler has more surface area to adhere

step 7. fill in the seams with one of 2 things, bondo (from an auto parts store) OR Ever coat poly flex ( I didn't have great luck with the poly flex on a different project, but lots of people use this material.

Step 8. use a putty spreader it's worth the expense. spread the putt smooth over the seam

Step 9- sand the seam area until smooth

Repeat step 8 and 9 until satisfied with smoothness

step 10- Prime time!

Take forearms and hand backs outside and hang them on a line. engage respirator (if you have one, if not hold your breath for a while) then spray a primer. I prefer duplicoat gap filler primer ( any primer will do. Spray it down.

Step 11 look for low spots go back to step 8. 9 then 10 if necessary. if not move to step 12.

Step 12- prime time again. The goal is to get two really good coats of primer on there so that the filler sections are covered

step 13- grab your paint I recommend this one, you can get it at home depot for $5 a can so don't get it on amazon ( ) spray it evenly no closer than 8 inches from the target. Smooth even long strokes. Using an airbrush on these would also be ok but a much more costly endeavor.

Step-14 spray it again. You want at least two good coats of paint.

With all this the armor will be glossy and great for adhering decals and such to it.

as for the insides, if you want to sand down the epoxy so it doesn't cut the heck out of your hands you can do that, or line it with a thin layer of foam from a craft store (or both). I then had a thicker layer of foam at the tops near my forarm and at the bottom near my wrist to wedge them in place. Then the gloves make sure they don't slide.

For the gloves I used crt 100 tactical gloves and put the hand backs on those. ( but there are other types out there.

As for the comlink, I didn't want mine permanently affixed, so i adhereed a noedymium magnet to it, and then put the other side (not adhered) on the inside of my forarmor and that is strong enough to keep it in place. Use a bar style magnet if you can, less twisting occurs this way.
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