The model is my ten year old son.
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Signing UpStep 1: The Breastplate
These measurements I then scaled down to my sons size.
2mm wire is a useful way to capture the unique contours of the wearer
Using those measurements, I fabricated basic frameworks around which to build the armour. Some pieces didn't require this, however, pieces that encircled a part of the body were best assembled around a frame; this helps maintain symmetry. All framework was fabricated from the same cardboard as the costume.









































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I recently introduced my four boys to Star Wars... and this is something we'd considered, but it seemed too daunting. It turned out really well, and doesn't have that "ahh-shucks-it's-homemade" look. Killer work.
Best of luck in the contest!
I've just read the Featured Author writeup about you... even more Kudos to you. You seem quite the remarkable individual. I look forward to seeing the latest CNC machine. all the best.