Picture of Samurai Armor (Total War: Shogun 2)
In this fine Instructable i will be showing how to make a full suit of samurai armor that i got the idea off of the game Total War: Shogun 2

The Armor i built was a fairly simple design but due to my small body structure was a little difficult to form the armor. how ever it worked out and i only messed up once during the whole build process! (drilled the wrong holes in one of the armor panels.)

I built this for fun based on several other instructables and my wanting of a costume that i built from the ground up and designed myself as well as having a sweet costume for dragon con 2012 ;).

the total cost of this project was $110 and took just under two weeks by myself :)

the armor i made is made out of HDPE 3/8" or cutting board. this armor made from a design from a video game will be used in stunts with sharpened knives and swords and compared to other armor types of the period made out of the same material after the testing well be doing a "deadliest warrior" style challenge were we have a face off in the many armor and compete with real swords!

what youll need:
2 sheets of HDPE plastic or your choice of armor material. you can use ABS,Sintra etc. (noobies use sintra its easy to work with and cheap!)*** Some one mentioned that you can get used acid drums made out of HDPE and cut them out, that way the armor is already shaped and rounded.***
Lots of thread i used a 7/8" ribbed thread to thread the armor together and about 12 Spools of it.
sewing machine
fabric (i used Brocade/Sari)
lighter for (burning the edges of the thread)
drill press
band saw
hot glue gun

this is a moderate build took only two weeks at full time hours but it does require a lot of drilling and threading.

feel free to make your own changes to what ever you like! like paints, fabrics and threads!

feel free to ask questions and share comments with others! best of luck!
ConnorF27 months ago

Exactly how much sintra do you need? I know you said two sheets, but what are the measurements of those sheets. I bought two 12 by 24 sheets of sintra off amazon but they look very small, and are probably not enough! Hopefully you still respond to comments on this page.

Towering Props (author)  ConnorF27 months ago
Hello! The sheets I was referring too were 24"x36". So yes you will need more sintra. Good luck!


Well done

Thank you I live in a small town and so I can't fin Sinatra or komatex any where for a reasonable price. I plan on wearing this at Momo con 2014 with my friend being in a geisha kimono
Towering Props (author)  pendragon6251 year ago
your welcome! ABS OR HIPS plastic is also a good choice because it can be formed with just a heat gun and is also very durable. both of these materials are usually cheaper then sintra if what you have doesnt work out.
have fun at the con!
I have a blue plastic barrel would it make good armor
Towering Props (author)  pendragon6251 year ago
i've heard good things about the barrels. some others have tried it with great results.
stunami3 years ago
Btw, how did you get the nice vertical bend on the shoulder pieces? And I see you laced on the front and back on one side, but how did you latch it on the other side?
Towering Props (author)  stunami3 years ago
they are actually 2 different pieces. the whole shoulder armor is bent a a crescent shape, once it was formed i just drew a outline on paper with it and added a couple inches and cut a piece out of the material based on the piece of paper.
pretty simple, just used a bit of epoxy and hot glue. im not sure what you mean by "latching it to the other i side" can you explain it a little more for me? :)
By latching, I mean, how did you close the body section on the sides? You have to get in somehow, so it has to open. Did you use clamps? Ties? Frogs? Buttons? Zipper?

For your helmet, it would look a little better and be a bit more accurate if the lamination are tied outward so it gets successively wider instead of inside so it goes towards your neck. It's why the flange on your helmet looks so narrow.

Also, where did you get the inspiration for this design? It's always nice to site your sources ;)
Towering Props (author)  stunami2 years ago
oh! well since this ive modified the basic design for putting on the chest... what i ended up doing was keeping the lacing on it as decorative trim and make 3 holes about 2 - 3 inches apart under the arm on both sides of the armor and using the same gold trim rope as a tie off. essentially i tied a knot at the front holes, (each hole had its own cord) and threading in through the back holes you pull tight and tie it off the the access on the front. its simple and works but you may need an extra set of hands to tie it off.

i agree on some of the armor bits needing to be more accurate but this was a 2 week build after all and not one of my major costumes. also the material chosen is incredibly hard to shape it to flange out like you mentioned and i also like to look up with out a band of plastic burrowing into the back of my neck and shoulders.

viola! http://www.instructables.com/id/Samurai-Costume/
poofrabbit2 years ago
Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!
Towering Props (author)  poofrabbit2 years ago
thanks so much! cheers!
Cmdr. Vik2 years ago
Great tutorial and awesome work!
kcli2 years ago
Quite impressive and obviously a lot of research went into your costume. You got me vote!
kcli2 years ago
Quite impressive and obviously a lot of research went into your costume. You got me vote!
kcli2 years ago
Quite impressive and obviously a lot of research went into your costume. You got me vote!
Can I use steel? I like this type of armor due to how light it is compard to plate armor and it would just be even cooler. The steel would be cold-steel.
oh yah you can use steel, it would have a great effect on it too if you added dents and weathering. i've personally never used steel for armor so i have no advice to give but im sure you could use the same instructions. here is a great diagram for metal samurai armor, note the difference in the chest as its one whole piece.
LogTrotter2 years ago
Hey !
I have made the chest plate armor with interlocking mats, it was pretty hard but people can punch and kick me with it on and it doesn't hurt.
Towering Props (author)  LogTrotter2 years ago
haha, funny how that works out right? well great job! ill be looking forward to seeing it finished!
LogTrotter3 years ago
Is the armor on your back the same as the front?
Towering Props (author)  LogTrotter3 years ago
yes it is, its pretty much the exact same template used. the only difference is that the ring/ hole for the neck is less of that on the front piece of armor.
LogTrotter3 years ago
Where did you buy the HDPE from and would those interlocking foam mats work? Cheers
Towering Props (author)  LogTrotter3 years ago
oddly enough Menard's had them with their plexi glass and acrylics in the windows and doors section. if your familiar with grainger you can also order it from them. they also have thickness selections which helps if you want thinner armor. you could very well use E.V.A foam (interlocking mats) would be easier to form but much harder to thread because it they give a lot cause of there density, you would also need to get the thinnest mats you could order but i personally recommend not using EVA. ill look for some other materials that would work and get back to you!
Towering Props (author)  LogTrotter3 years ago
So I did some more looking around I found out yoga mats are the same material as eva foam. Once heated and formed it does harden and keep shape. Your more then welcome to try that out for the armor. I haven't attempted yoga mats yet but im going to try soon for a differnt project.
Ive bought some foam mats and i'm going to start making it soon.
Towering Props (author)  LogTrotter3 years ago
Alright let me know how it goes, best of luck.
stunami3 years ago
Cool design. It looks good.
Aleator7773 years ago
Great work. This is super cool!
rocketman73 years ago
Better Shoes?
They would not protect, and get wet very easily in your area or snow.
Towering Props (author)  rocketman73 years ago
i have made a seperate sandals out of bamboo with ayou heel lace since then to be more period but they really did where sandals in battle. some late period armor from the shins would come down ontop of the foot but do to restricting mobility wasnt very common.
in battle the last thing you would worry about is getting your feet wet haha. :)
EmcySquare3 years ago
The Flag is called Sashimono

Could be a little taller than that or your pals won't see you in the battle field

Great Job !!!
Towering Props (author)  EmcySquare3 years ago
thanks was trying to find it!
yah i wanted to make it tall but going through doors would have been a bit of an issue haha xD

tinker2343 years ago
nice job love the armor
monsterlego3 years ago