Step 1: Moulding the 3 Inch PVC Pipe With a Heat Gun
First, you need to cut the PVC pipe to your desired length of your knee cap. Then, I used a Saw-all to cut a vertical line down the pipe. Next, heat the pipe evenly with the hot air heat gun to soften the plastic. Then, use a 3 inch putty knife to pry apart the pipe and mould the pipe into a U shape. Always wear thick leather gloves during the operation or you will burn your hands!!
Step 2: Drawing the Template and Cutting It Out
Once the PVC has cooled, use templates drawings of the knee armor and a marker to draw out the general design of the knee armor to be cut. Use the template provided on a copy machine to enlarge to desired size.
Next, use a Dremel cutting tool to remove to large pieces and a router bit for fine detailed work.
Step 3: Fine Tune the Shape of the Knee Armor
Use the Heat gun again to double check the shape of your knee armor.
Step 4: Making the Side Gun Ports
I found a scrap piece of wood in the garage and used a saw to cut out the general shape of the side ports. Next, I used a disk grinder to shape it. Hand sanding will work also but the grinder was at hand so it saved time. After sizing the side ports, I pre-drilled holes to prevent splitting the wood and used 1 inch wood screws to ancor the blocks in place.
Step 5: Making the Gun Barrels
Again, I found a scrap piece of PVC water piping small enough to use as barrels on the side ports. I cut them to desired length. Then, cut smaller pieces for the 3-D effect of the barrels. Using the heat gun and needle nose plairs to strech the small PVC pipes to slip over the barrels. Another way to do it is cut the smaller PVC pipe vertical, slip it on the barrel and heat it up with the heat gun. After it cools, use a drop of glue on the pipe ring so it won't fall off. Finally, I used large picture hanger from Ace Hardware on the inside of the knee armor to connect the strap that will go behind my knee to hold the armor in place.
Step 6: Attaching the Gun Barrels
I used a hot glue craft gun to anchor the barrels to the side ports with the wood screws in the middle of the barrel.
Step 7: Final Paint Job
Finally, apply a primer coat of paint to the knee armor, then a metallic silver coat. Next, apply a liquid latex coat to the areas you want to keep silver, allow to dry. Then, apply your final yellow coat of paint. Once this has completely dried. Use a eraser block to rub off the liquid latex and expose the silver below. This will give the armor the appearance of battle worn look. I added battery operated LED lights to my Boba Fett costume so it really stands out at nite!
Step 8: Party Party Party!!!