Introduction: Alphonse Elric Armour in Aluminium

About: I have a Advance Diploma of Multimedia Design, have a lot of graphic/industrial design work experience. I'm also a trade qualified Metal Fabrication Engineer. Recently I have given up all this to develop my sk…

For anyone wanting the patterns I've attached them to this instructable now, "pdfs.rar"

My current project, the Alphonse Elric suit of armor from the anime Full Metal Alchemist. I have no particular interest in making armor but I thought it would be a great way to pratice my metal shaping. I also learnt to make chainmail so I could fill some of the gaps, in between the arms, legs armpits etc. it won't be wearable, more of a static display. Once finished it will stand at about 2 metres tall.

I started out with a plastic model of Alphonse, using it to make patterns for all the parts I would have to make. I merely used masking tape to replicate each face of the parts. Then I scanned them in and scaled them up, tracing them in solidoworks to make the patterns. I then had them printed out 1:1 scale on A1 paper. It was then a simple matter of cutting out and sticking them on to the alu sheet and cutting them out.

Note though: Some of the simpler parts I did not make patterns for. There is about 25-30mm of excess on some of the pattern edges but not others. Hopefully I'll have it finished by the end of the year, time permitting.