I wanted to have real looking armor w/o being weighed down by metal. So I created armor out of latex. Its actually a really simple process:
you can find all of these materials at Douglas and Sturgess
by draw out on paper/cardboard how you want the breast plate to look. This will just be the 2D design.
into the 3D design of the breast plate. Spray the clay mold with a parting agent. This will let the clay separate from the plaster.
Pour the plaster
over the clay model. Follow instructions for mixing the plaster. Make sure to build a wall around our mold before you pour so the plaster doesn't run everywhere. Once the plaster dries remove the clay from the plaster. I had to use a toothbrush to get some of the clay out.
Fill the negative plaster mold with liquid latex
. I painted it in with a paint brush.
Once the latex is dry, paint the breast plate with a latex paint. I added hammer in snaps to the breast plate and the corset so it was removable like the real Xena outfit.