Step 4: Cast Breast Plate Armor

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:

Materials: you can find all of these materials at Douglas and Sturgess
Modeling Clay
Liquid Latex

Design Armor by draw out on paper/cardboard how you want the breast plate to look.  This will just be the 2D design.

Mold Clay 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.