Step 6The Armor
First, cut the bottom off the blue t-shirt. Then, use the stitch witchery to fuse the middle of the star to the shirt. You'll want the points of the stars to be loose so that you can sew scales under them. The star pattern came from www.elegantmusings.com. When printed with Windows as a fax print, it's just about the perfect size and shape.
Then cut scales. Cap estimates that he and his friend Dan cut about 200 scales total. They are around 2" x 2". After the scales were cut, Cap creased each of them down the middle with an iron to prevent them from curling.
We then painstakingly pinned each scale down and sewed them on in rows. I had the best luck on my machine with the tension turned all the way up, but it really could have gone higher because I kept having tension issues. Once the scales were all sewed on, the tips of the star were glued down and then we sewed a long piece of vinyl around the neck and pinned the back down with safety pins.
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