Introduction: Metal Arm (The Winter Soldier)

This is going to be A instructable for Bucky Barnes' (The Winter Soldier's) Metal arm.

It was really affordable to make and pretty easy to make.

In the beginning it will look completely ridiculous at first but trust me, in the end it will look amazing!

Enjoy crafting!

Step 1: The Base

This is the first step and its important, actually every step is!


You will need:

  • Cardboard
  • Tape

Start with a large cardboard box and make three parts around your arm, the forearm, upper arm and the shoulder then tape them in shape. The shoulder and upper arm should be tapped together but the forearm should be left separate.

Make sure both parts are firm with lots of duct tape wrapped around and around. Try to round the shape as much as possible, this will look very silly atm.

get some fabric and connect the fore arm and the upper arm to create a elbow. I used a sock as it was easy to work with. It has to be a stretchy fabric or you won't be able to move.

Step 2: Paper Mache

This is where you will be able to make the shape of the muscles and curves.


You will need:

  • Paper mache base
  1. 3/4 white glue to 1/4 water
  2. 1 part flour to 5 parts water... boil about 3 minutes and let cool
  3. 1 part flour to 1 part water.
  • Newspaper
  • Reference image

Start to paper mache the arm shape you have. This is one of the most important steps to making it look as accurate as possible.

Try and make the shapes round and anatomically correct. Reference images are really useful at this point.

This is going to take so many layers to make it look muscles but be patient, it will make it look amazing at the end.

Then use a primer like gesso once the mache is dry and cover it in a additional layer.

Step 3: Metal Plates

This part is definitely the longest but be patient :)


You will need:

  • Parchment paper/ Tracing paper
  • pencil
  • craft foam
  • hot glue

Okay so now comes the longest parts. You're going to have to draw out all the marks in the arm, don't worry to much about making it as accurate to the movies/ comics as it will take SO long to get it perfect. Just keep similar to one reference image but try not to make it too small in intricate as it will make the next step a lot harder.

You now need to transfer every line or section from the arm drawing onto foam sheet. To trace the lines I used parchment paper, usually used for cooking as when you draw on it with pencil and flip it you transfer the exact lines when you draw over it again on the other side. I also used fun foam to make the plates as it was the cheapest to get a hold off.

Once you have all the plates (don't forget the star) drawn on to the foam sheets, cut them out and lay them how they would be positioned on the arm. Then get a hot glue gun and stick each one down on the outlines you've drawn on the arm.

When you glue the plates down make sure you mold it over the muscles you created before hand, the hot glue will allow it to mold the shape then when it drys it will stay in place nicely.

Step 4: Painting and Finish

Finally we're almost done! (Sorry for the bad picture above)

You will need:

  • Primer
  • silver spray paint
  • red acrylic paint
  • craft foam

Now you have all the pieces of foam stuck down and dry you're going to want to paint the whole thing in primer or gesso to allow the pain you use to hold.

I used silver spray paint To make it silver and then painted the star with red acrylic.

Additional details:

You can wear a black fingerless leather glove to hide your hand and make small caps for your fingertips to make it look realistic.

The cardboard can get uncomfortable on the skin so maybe wear a long sleeve shirt underneath or I covered the inside with thick foam sheets to pad it out.

You should now have a great cheap cosplay!
Thank you for reading <3

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