So my daughter decided she wanted to cosplay TWS. I started looking online and just couldn't find the right arm piece to make. I then came across a post on RPF (would give credit if I could find again). They said they used the left arm from classic iron man pepakura foam file. So I gave it a shot.
I used the classic iron foam file to make these. (I lengthened the bicep a little closer to the elbow and the upper shoulder part was lengthened also)
Thanks to jf customs for file
First bicep piece was a little big, forearm was fine. I re-scaled bicep and used Evil Ted method to draw out design. I cut out the shapes using foamies and glued with super glue.
I then plasti dipped, sprayed with metallic finish and finished off the star with some red acrylic paint. I strapped it across chest and back with nylon webbing and a plastic flat buckle. Although this method worked out great it was not strong enough and it tore in one spot after one con. I decided to coat it with fiberglass resin after repairs. (big mistake) The paint and plasti dip started melting away. No worries, I wiped away resin, paint and plasti dip. This took me back to the foam base. Now I was able to coat foam with resin finished off with metallic spray paint and finished star again.
I then decided to remake bicep piece using resin only method. To bad I had scrapped original scale size it turned out too big. It was looking awesome. I was going to paint the star on this one instead of making it part of design.
Hope this helps somebody else.
I later decided to remake the arm piece using same method but coating with fiberglass resin and was just going to draw the star. Two coats. Unfortunately it was a little big since I scrapped the original file.