While 90% of the armor in this tutorial will be comprised of Wonderflex, it's important to know that the best results come from using a myriad of materials. Wonderflex is a very capable material, but there are certain limitations to what you can accomplish with it. I'll also be using other materials to accent and enhance the appearance of the basic forms, and these will be called out and linked when appropriate.
In the images above, all armor parts except the helmet were made from a mixture of Wonderflex and Apoxie sculpt. If you're interested in the construction of the helmet, check out my other instructable detailing how to make helmets from videogames!
Step 1: What is Wonderflex?
Wonderflex is also self-adhesive, meaning if you heat up two sheets and press therm together, they will bond to one another as they cure. The more you heat the material up, the stronger this bond will become. I prefer to use a heat gun but you can also microwave smaller pieces if you prefer.
It is available in three thicknesses (.35, .45, and .69") and is shipped/sold in rolls. I buy mine from The Engineer Guy here in Atlanta, but there are plenty of distributors online who also sell it.
Even the thickest of their available products is still pretty thin for very good results, so you'll see in later steps I often double or triple layer the material to make curves smoother and cleaner.