Armor comes in all forms, and scale mail is an attractive option. You can fashion it in a few ways – from expensive heavy materials to lightweight and more affordable options like styrene. Over at White Rabbit Costuming, cosplayer Vartazian breaks down how to make scale mail from styrene, fabric, super glue, and body armor. It’s a beginner level tutorial, so all you need is time and patience. Here’s info on the specific styrene and creating the scales:
First, you need Styrene (Also known as Plasticard.) You can find packs of 2-4 sheets for about 6-8$ per pack. Get them at your local train hobby store. Getting .10 grade works but anything up to .2 will work (Anything thicker will be more difficult to cut.) You will get about 30-40 scales per sheet of Styrene (For scales 2inx1in tall)
Next, make your trace [sample scale]. This is important, make sure it is symmetrical (you will thank me later). My scales are 2 inches tall by 1 inch wide. Trace in pencil. (Dont lose the trace!).
Read more at White Rabbit Costuming.