Though you can craft armor relatively inexpensively using materials like EVA foam, that’s not the only cheaper possibility. You can turn to plaster of paris bandages to accomplish the task. Tumblr user madeinmirkwood used a material called ModRoc, a bandaged used for modeling, casting, and crafting, for making Thranduil armor from The Hobbit on a budget. They detailed the process, and it begins with wrapping the parts of your body you want to make armor for in cling wrap (unless you happen to have a tailor’s mannequin). Then you layer the ModRoc over the cling film. Once it’s completely dry you can finish it with details:
adding in detail with wool and glue – i got the detail and design on the armour by dipping wool into pva glue and laying it on the armour. Again this is quite messy and it does take a bit longer to dry but it’s strong and quite effective when it does.
And before you begin painting, madeinmirkwood offers this tip:
(optional) layer of paper mache – to smooth out the surface i cut squares of newspaper, covered them in pva glue and layered them onto the modroc. This isn’t vital but i found it was way easier to paint with the paper on top.
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