Introduction: Alphonse Elric Armour in Aluminium

Picture of Alphonse Elric Armour in  Aluminium

For anyone wanting the patterns I've attached them to this instructable now, "pdfs.rar"

My current project, the Alphonse Elric suit of armor from the anime Full Metal Alchemist. I have no particular interest in making armor but I thought it would be a great way to pratice my metal shaping. I also learnt to make chainmail so I could fill some of the gaps, in between the arms, legs armpits etc. it won't be wearable, more of a static display. Once finished it will stand at about 2 metres tall.

I started out with a plastic model of Alphonse, using it to make patterns for all the parts I would have to make. I merely used masking tape to replicate each face of the parts. Then I scanned them in and scaled them up, tracing them in solidoworks to make the patterns. I then had them printed out 1:1 scale on A1 paper. It was then a simple matter of cutting out and sticking them on to the alu sheet and cutting them out.

Note though: Some of the simpler parts I did not make patterns for. There is about 25-30mm of excess on some of the pattern edges but not others. Hopefully I'll have it finished by the end of the year, time permitting.


galacticdominator (author)2011-10-03

I can't get the fmamotorcycles link to work... a thousand curses on my rotten luck. I finally find some schematics for Als armor and the link doesn't work. Please, let me use your hard work to build my much less metallic version for a costume thing. Can I get a link to a working version of the site or an email with an image file of the patterns you used? I would be very grateful.

Hey, Shoot me a pm with your email and I'll send it to you directly.

how can we scale these patterns to ourselves?

lgraham1 (author)melrajas2017-10-04

If the pattern is a little over 2 meters tall then scaling it down %10 should make it about 6ft scale.

Could you shoot them my way to by chance email is

I suppose my pricate messages aren't working. I got yours but it seems you didn't get mine.. no matter, anonymity was fun while it lasted. My Email is I'll just delete the comment after I recieve the patterns. Thanks.

Private message shot, thank you.

The error message I was getting is:

mysql error: [-32000: Cache write error] in CacheExecute(/home/fmamotor/public_html/files/cache/9f/adodb_9f28f7fdab3ec8735c837e0639e2857b.cache, select cParentID from Pages where cID = '57')

SideTracked350 (author)2017-09-07

Oh also could you maybe put a reference dimension on the helmet back plates like you did on the front? I printed it out full scale and the borders are the same and my ruler matches the dimensions from adobe but the pieces look massive. They look like they could wrap all the way around my head. What should the final overall length be of one of them?

MichelleF14 (author)2015-07-26

I noticed the dome part of helmet did not seem to be anywhere. Am I missing it or was it never a part of the pattern?

zork the destroyer (author)2014-01-30

can you please add patterns fro the simpler parts

łbranny (author)2012-07-02

Can you add the "TopLegOutside" pattern?

lgraham1 (author)łbranny2013-08-30

the Top Leg Outside wasn't in the RAR package you'll have to download the individual pdf from the page.

staffel32 (author)2013-05-27

Seem to lack the front cone in the helmet. I cant find it.

mdonahue38 (author)2013-02-09

did you ever finsh the project and do you have pictures of it

jrbrother (author)2012-08-17

i tried right click and save link as and it didnt work so could you send it to me by email my email is

TheFullMetalAlchemist (author)2012-08-06

Did people try right click/save link as? Works for me.
This is the instructables link above the comments I am talking about.
My old web page doesn't exist anymore.

luvEdElric (author)2012-08-04

Yeah, I couldn't get the link to work properly either. When it loaded it just showed a bunch of code or something. Could you please send it to me as well.

jrbrother (author)2012-07-19

hi i been wanting to make Alphonse Armour for some time but could find a pattern at all i tryed the link but it didn't work could you send it to me by email

łbranny (author)2012-06-27

ok, i have small problem. I cut off the elements, but i don't know how to fit it together. Do you have plan, or something like that? It will be very helpful. i will be thankful for the solution

penny1958 (author)2012-06-19

hello there - I too tried to get this file and it wouldn't work - you have done a great job. we are trying to do a skit and this is my costume - so if you can help me in anywhere by sending these files patterns to my email that would be great - keep up creating you are very good at it.
my email is

thanks so much

Hi Penny
Did you try the link on the instructable?

Have fun

poplinfab (author)2012-06-05

i have a cnc laser and am interested in making this.

TilTherWasU (author)2012-06-01

I tried to use the link but it just won't work. I would really like to have a copy of it.  Can  you send me an email with the file?                                                                                       

Thank you,

Hi Norma

I've attached the pdfs to this instructable, so you can get them here.

SHIFT! (author)2012-05-09

Question: Is this Alphonse's design from FMA or FMAB? Because even though the two look somewhat similar there are varying differences between.

Please post a full Step By Step when finished! Instructables could use more Anime related projects.

I worked off a model from the original FMA
Can't wait to get it finished but I am sans workshop at the moment. (in a city apartment atm, sucks!)
As soon as I get some space I was going to get back into.

Any chances we might get Ed's automail, perhaps with interchangeable "transformations"? That thing is awesome!

łbranny (author)2012-04-04

I have one small question it's 2 mm aluminium? Or 3 mm? Or mayme 1 mm? I want do it to wear, and weight it's important to me :)

I used 1.6mm

Modern_Mongoose (author)2012-04-22


Thanks Mongoose!
Yeah I'm building a new website. I'll attach the PDF to this permanently when I get home from work.

ironsmiter (author)2012-04-10

Don't suppose anyone still has this pattern?

The account at fmamotorcycles is suspended... :-(
If possible, it'd be great to get a copy of the pattern uploaded and attached to the 'ible. Or just uploaded into someone's account, and linked here in the comments?

Duct Tape Dude (author)2010-11-18

"It won't be wearable, more of a static display" Is there any way to modify it TO wear it, or is it just not possible?

It would be possible, You'd just have to alter the scale. For this size my head would be in the neck somewhere. Its a bit over two metres tall. It would just be a matter of shrinking it to the size you require. I only made it this size because I wanted it big and imposing, much like the cartoon.

can you number the patterns and send me so i can understand how to join them cause i am a little confused here :(

I don't think numbering will help you, like I said in the description these patterns were made for metal shaping. You can't just cut them out and expect them to fit all together, they weren't designed like that sorry.
You'll just have to play around a bit. That photos of all the patterns laid out would be a good start, that how they go together basically.

do you have finished photos of armor?

D_zeno (author)2010-10-13

Do you have special equipment for welding aluminium and is it hard to weld aluminium???

When I started looking in to welding aluminum years ago lot of people were saying it was really hard to do blah blah. It isn't really that hard, maybe a little trickier than steel but not much. It basically come down to practice. It only probably took me a few hours of practice to get pretty good beads down with a TIG welder but once you have the hang of it and you practice your beads will get better.
I use both a TIG ( Tungsten Inert Gas) welder and an oxy/acetlyene setup too.
Both units are pretty standard in metal fabrication. The only thing
that really changes between say steel and aluminium is the shielding gas and
the mode of current. Aluminium is welded use AC ( Alternating Current) while steel uses DC ( direct current)
So basically as long as your welder is an AC welder or a switchable AC/DC welder and you have the appropriate shielding gas (Argon) you can weld most aluminium. Most people welding steel will tend to use a Argon/Co2 mix or other combination which don't work well for TIG welding.
You can MIG weld aluminium too but the results aren't quite as neat as TIG welding, well atleast for thin guage materials anyway. As long as you have the correct wire and Argon.
The oxy/acetlyene is a bit like TIG except you use a bottle of oxygen and a bottle of acetlyene to generate a naked flame to melt the metal to be welded.
It's alot harder than any of the other welding procedures I use but it comes with the advantage of the weld being pretty much just as soft as the bits of metal welded together. This makes it easier to hammer out the weld making it near invisible between sheets. Oxy/Actlyene is very useful for that reason when shaping sheet metal. Both TIG and MIG leave brittle welds so when you
hammer them out they'll crack usually.

There is alot to go into but thats about the basics. if you have any other question drop me a message.

Oke, thx
I think for wath I had in plan this type of welding is too hard and inaccurate.
Because of the precise mechanish.

Anyway thx for the quick answer and tips ;)

ultulva (author)2010-07-18

wonderful work. I am a big fan of the unique armor this series came up with, very suave.

mrmoonshineman (author)2010-06-08

very cool, i used the same method to make a frog out of some sheet metal from an old fender. i built a model of what i wanted out of manila folder cardboard (which is nice stuff because is can be whittled with an exacto knife) and then cut it apart etc, etc. having an air nibbler was a real time saver, i'm sure that would work even quicker on aluminum. looking forward to the final product!

Void Schism (author)2010-06-08

I take it this is a work in progress then?

Yeah it is. weird my description of the project has disappeared.

It's currently a bug with slideshows :( HQ are aware of it I think.

Thanks, I was about to type it out for the third time ahahaha.

HQ have fixed this problem now. Try again and it should work!

I can't wait to see the finished project.

About This Instructable




Bio: I have a Advance Diploma of Multimedia Design, have a lot of graphic/industrial design work experience. I'm also a trade qualified Metal Fabrication ... More »
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