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This is the window that should pop up.
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With the cod I examined the 3D render on the PC and determined that there were three major parts for construction as seen here...
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I took into account of the valleys (shown below) and simply added it to the cutout template from the pepakura file to deal with later which I have a plan to use a 3mm layer to give it depth which I will show you later.
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Here you can see where I added extra paper to the valley to fill the gap...
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Here is an example of how I set the pieces together to do a fit test. Fit testing is important to do BEFORE you touch foam or cardboard. Simply use scotch tape and put the corresponding pieces together using the pepakura program as a template.
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Here is an example of the materials I used.
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I'm planning on building a costume like this, so am watching very closely. :) Thanks for sharing your progress!
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If you want a more durable armor, look on the resource page of the 501st legion Vader's fist. There you can get stores that sell Stormtrooper armor which includes the bodysuit. You can then cut and refinish the armor to your needs.
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Yes, you can purchase armor pieces from various places, but this a tutorial of my build using foam. I will post a link soon on how to make a cast of your foam armor to show you how you can go 'rigid'. With a little patients and skill development you'll be standing in your work area marveling at your creation from $150 that people sell online for 3 times the amount. But, the bodysuit for Stormtrooper can be easily purchased online by looking up wetsuits. For this build you'll want brown. Most wetsuits are black or neon. For a Sith Acolyte you can use black tee shirts and black pajama bottoms because their look is a lot like the Ring Wraiths from LOTR movies.
Luckily, the way this armor will work (at least I hope) it will be mostly out of the way and not be bulky. Whereas, if you were sporting a FULL body suit of armor, yes being more sturdy is important. See the pic below for my full suit I did for 2013 Halloween. The shin pieces weren't attached very well because I rushed the job and built the suit in 2 months. Which is why I am starting now and giving myself plenty of time for this year. Ha!
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I had to change my approach to the guantlets, but sometimes that happends. The original looked like this...
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Because I left the side pieces out the frame couldn't keep the curve and would lay flat. So, I decided to fill in the space and intend to add layers to show the gaps by painting it a darker color to let the top pop more...
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