I thought it should be pretty easy since they are so similar. I can use my experience from the Mega Man costume, and make improvements along the way. The one thing I wasn't going to change was the finish. I think the fabric (cotton in this case) wrapped components make a great looking real life conversion of cartoons/video games.
This is another lengthy instructable so I will break it down like this:
3. Proto Buster
5. Gloves & Bracers
The complicated components will each have multiple pages.
Step 1: Shield - Step 1: The Base
It takes me a good bit of time just to find the right materials that will allow me to create what I am looking for. I had some immediate thoughts about the shield and they turned out pretty good.
I needed something large, made of heavy plastic with a curve to it. First thing I thought of was a garbage can. But they don't make that many smooth surface cans, I was in luck with BRUTE. I was able to get their smallest garbage can. Although it was a little costly, well worth it, since it worked out so perfect.
BRUTE Garbage Can
Roll of Paper
After getting all the materials I needed I made a template from a roll of brown paper that I have. I took a large piece of the paper and folded twice. Once along the vertical length and the second time along the horizontal length (like making a paper snowflake). I drew a line that would make up 1/4 of the shield, then cut. Unfolded it and had a complete template for the shield.
I then put the template on the garbage can. Since I wanted the shield to be concave in both horizontal and vertical (and since the garbage can wasn't tall enough to get the shield in one piece), I used 1/2 of the template to cut out the shield. The thing that I needed to figure out was the bottom edge of the triangle needed to have a curve to it. So I added an inch to the bottom line, then made a curved line up to the sides of the shield.
After marking the same template on both sides of the can, I cut them out with a hole saw. The reason I used this was it cut pretty good and fast, and allowed me to make a curved cut. I then cut a strip that was almost the length of the widest horizontal line on the shield. This is the bonding strip that I will glue the two pieces of the shield to.
Then sand down all the edges, but they don't have to be clean. Just get ride of all the burrs. Also sand the bottom of the triangles (where the two pieces of the shield will meet. Also sand the surface of the bonding strip. The plastic epoxy bonds better with a roughed up surface than smooth.
In one of the two pieces cut a hole out for a lookout. For this I used the utility knife since I needed a nice clean line. I had to be careful not to go too hard or else I would over cut. Not a huge deal as it shouldn't effect the end product.
To attach the pieces make sure you are ready since the drying time is 5 minutes. Create some kind of a stand that will keep the shield steady. I held the sides with some scrap pieces of lumber. The top and bottom were lifted just slightly giving it that concave form. When you are all set mix the epoxy and apply liberally to the two pieces of shield and the bonding strip. Work fast since it is a long joint and you only have 5 minutes.