Cardboard Samurai Armor That Looks Authentic

Cardboard Samurai Armor That Looks Authentic
I have to give credit to a lot of people for this instructable, particularly Atrophius for his award winning instructable, which was my inspiration. I actually wanted to create a whole set out of sintra like he did, but because I'm out of work at the moment, I decided that cardboard was a more economical decision. Also, I didn't have enough time to make many ancillary pieces such as the leg and arm armor, and helmet. So this current piece will only include the body armor (do), and includes the shoulders (sode) and dangly crotch/ butt covers (kusazuri). Next year though, I'm going all out, and hope to post an even more awesome instructable with a top notch suit.

With that note, I did diverged from Atrophius' armor in many ways. The first is that I really wanted this to have an authentic look, and decided to go with a layered scaled Do instead of a stacked flat version.

I apologize for the lack of pictures for the Do and Sode, but I accidentally deleted them off my camera. I don't know how, or why, but oh well, they are no more.

This suit of armor got me many compliments, and I think it was totally worth the time and effort to make everything look good. Many people couldn't believe it was actually made of cardboard. It turned out sturdier, better looking, and funner than I expected!

 
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Step 1Materials

Materials
This was a not a particularly demanding project when it came to materials. All I needed was:
- Lots of cardboard (single corrugated is easier to work with than double, but weaker)
- Lots of yarn
- 2 cans of spray paint (I would use a name brand like Kreylon. I used a no-name brand for one can, and it didn't have quite the shine.)

Tools that I used were:
- Yard stick
- Tailor's measuring tape
- Razor knife/ box cutter
- Clamp vices
- Electric drill with 1/4" bit
- Sharpie

Time:
- The time spanned a couple months, but I'd say that if you're handy, it should take two weeks of 2 hours a day during the weekdays, and one day on the weekend (for painting)
- About 30 hours

Resources I used were:
For inspiration
- Atrophius' insutructable
For details
- Sengoku Daimyo
For accurate pictures
- Samurai Store
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34 comments
Aug 26, 2010. 4:52 PMCheezpaper says:
Nice instructable, but why is this in the ninja guide? Lol Ninjas and Samurai were enemies.. But I ain't blamin this on you, it's Instructables' fault.
May 27, 2011. 8:14 PMchainedflesh says:
Depends on the time period you are speaking of. Before ninjitsu was formalized a Ninja was little more than a Samurai in disguise. (And they never wore the hooded pajamas. That was an invention of Japanese dramas.

The "Ninja" costume that you see in movies is actually the uniform of a stageehand from traditional Japanese theater. The black costumes were a cue for the audience to ignore their presence. Often tthe costumes helped them blend into a ddark backgrouns so that props like stormclouds looked to move on their own. The association of this costume with Ninja comes from a play where the main character was to be assasinated. The director had one of his actors dress up like a stagehand so the audience would ignore him until the last minute. For its time this was an incredible mindfrak. It caused a lot of hype and even some controversy among the theater crowd.

But it proved so popular that it was emulated by other theater directors and suddenly dramas had assasins written into them left and rright just so this technique could be used. In Japanese popular culture this became the iconic ninja.

Actual ninja looked like they were little more than peasants and laborers. People the nobles would not give a second glance to, much less expect to pull out a large dagger or shortsword.

If they were to perform a mission under the cover of darkness, then sometimes a hood would be worn and they would have clothes dyed in dark blues, greens and rusts. Simply because truly black clothing would stand out more at night

Hope you find this information valuable.
Mar 21, 2011. 9:09 PMKatanaman says:
Wow that's not bad for cardboard, although so far the closest I have seen is the Samurai armour by Atrophius.... But if I may add some constructive criticism? You are wearing the Katana wrong, the blade edge always faces up so when you draw the sword you immediately are in a position to strike from the moment it leaves the Saya (scabbard).... Samurai always wore 2 swords, The Katana and the Wakizashi and is called daisho, literally meaning big-little (dai = big sho = little).
Sorry I ramble a bit somethimes, thanks for your instructable
May 27, 2011. 7:56 PMchainedflesh says:
There is no correct direction to point the edge when wearing a katana. It all comes down to personal preference. Katana wear traditionally worn with the scabbard either loose in the Obi or hanging by a chain or cord. When drawing the blade for a draw cut, the scabbard could be rotated to the wearer's preference for which form of draw cut he would like to make. Which makes perfect sense. If you positioned you scabbard so that the only way you could draw it was in an overhead fashion, you would be faced with a lot of horizontal or rising strikes that you could not defend against with your draw.
May 17, 2011. 2:35 AMKatanaman says:
The photo in your link does show the Samurai with the blade edge (Hamon) facing down, traditionally that shows a passive stance as the Samurai is posing for a photographer, so he faces the Hamon down to show his intention, also if the Samurai had his Katana on the right of his body with the Hamon down and the Tsuka toward his rear would also show intention of peace, otherwise the Hamon up is a "battle ready" stance.... When you display a Katana you would have the Tsuka (handle) facing to the left and Hamon up to show the true intention of the owner, and it is considered bad manners to draw a sword in the prescence of company...
I apologise if I seem argumentative, I do not wish you grief, I only want to share information from what I have learned from over 25 years of study in both Daito Ryu Aiki-jujutsu (Samurai training) an Iaido (swordsmanship).
Peace to you friend.
Sep 20, 2010. 9:32 AMNeovenetar says:
Is that a real live blade katana??? or is it an iaito sword? or really good prop?
Sep 25, 2010. 4:03 AMNeovenetar says:
what, so it's metal?
May 16, 2011. 12:05 AMNeovenetar says:
I think that's either a tachi (predecessor to the katana) or he is holding it in his hand.
Oct 14, 2010. 4:18 PMPizzapie500 says:
I'm not sure but I think it's called a jinbei not a zinbei. Because on google they had nothing for zinbei then the closest they had was jinbei and it looks like that
Dec 28, 2010. 9:28 AMPizzapie500 says:
OOOH I MADE IT! IT LOOKS AWESOME! I combined your ible with Atrophius's one so it now looks like this:
Samurai.JPG
Sep 28, 2010. 6:58 PM2moomoo11 says:
you did good on this i make it and it looks greats but lacing was hard
May 4, 2010. 12:33 AMRowen27 says:
great instructable, I would love to see the pattern for the helmet even if you didn't finish it.  it would make a great addition to this instructable, or even give it an instructable of its own.
Jul 1, 2010. 5:52 PMthe_burrito_master says:
Can you tell me the dimensions of your katana I'm going to be forging one and i want to know the thickness of a real katana. I mostly wanna know the with not so much the height.
delete.jpg
Sep 21, 2010. 5:32 PMGeneral Eggs says:
Most Katanas have about 1/8th inch thickness and are about 1 inch wide.
Sep 22, 2010. 5:58 PMthe_burrito_master says:
Well I actually found a chart on the net of variously sized katana's, looks like mine's a little skinny, but that will improve cutting ,it'll just take away some of the strength.

V Here's my katana it's quite a bit shinier now it's just an oldish picture !
47459_151931501499047_100000465955812_440707_2264237_n.jpg
Nov 3, 2009. 6:49 PMPlayer 1 says:
very nice tut, but the thing is, samurais dont wear ninja mask, only ninjas do... to make your tut even better, u should create a way to make a samurai helmet, instead of wearing a ninja mask... ninjas and samurais are not the same... i hope you dont find this critizism offending, i dont mean to offend you, just adding knowledge to your brain... i call it friendly critizing or learning by critizism. k bye
Nov 5, 2009. 12:57 PMcrapflinger says:
to be honest...even if you had finished the full suit (helmet and legs etc...) you probably still would have gotten a lot of "hey look a ninja"....some people don't take the time to care about things like accuracy
Nov 6, 2009. 6:40 AMKaelessin says:
I can attest to that. . . .every time i've included one of my katana in a costume regardless of whatever else i was wearing i've gotten "ninja" yelped at me more often than any other guess. Even when i went as Vicious from coyboy beebop . . .a suit + katana still makes a ninja apparently!
Apr 27, 2010. 6:30 PMflubs says:
 try wearing a sign that says ''not a ninja plus a katana.. see wat happens
Apr 17, 2010. 7:40 AMthe_burrito_master says:
lol jacki chuns uniform on the left. (guy from dragonball)
Mar 8, 2010. 5:55 AMmanzi says:
looks like 3 kingdoms plate armor.. toss in a helmet and a spear and you'll be guan yu.
Nov 2, 2009. 9:37 PMDainiusGB says:
 I made one of these for a history project, although the only color of spray paint i had at the time was red so it came out looking like a freaking fire truck. Although for me the hardest part was getting into the chest piece. It took me a really long time to string up all the pieces. 
Nov 2, 2009. 3:01 PMSNiPERSeyes says:
if only you could some how incorporate duct tape this would be the most amazing thing ever
Nov 2, 2009. 1:20 PMcowscankill says:
Freaking awesome! I love Samurais and cardboard! :D
5*!

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