The Chest/Back
To sculpt the chest you'll need either an upper bodycast of a person, a mannequin that's similar to the final size of the wearer, or alot of time to custom sculpt a mold from just measurements of your own body.
We did ours the hard way. We hand sculpted ours from measurements. We knew how large existing scout armors made by fans were already by taking measurements of some at local sci-fi conventions. We then proceeded to take those measurements, adjust them to our liking and sculpt out the chest armor.
There is a rectangular indention in the lower right side of the chest. A grey decal covers this recessed area.
Our chest measures, 35.5 cm wide, 31.75 cm tall, 15.25 cm wide neck opening. The flat areas in the chest going vertically (up and down ) are 3.2 cm wide. The horizontal flat areas are 3.8 cm wide.
Once you have created your master mold or sculpture, you'll want to refer to our plaster casting and vacuumforming sections to make your final vacuumformed armor parts.
The Back
The Back Armor is like the front armor, only different. It has a hump attached to it. Alot of propmakers swear that the back armor is a chest armor with the hump attached to it, but I am not convinced that it is. It is similar in shape, but a few key points keep me from thinking that both the back and front are from the same vacuum mold.
Here is a diagram of the measurements for the back mold.
The back measures 14 inches wide (35.5 cm), 15.5 inches (39.5 cm) tall and the hump was 8.5 inches (21.5 cm) tall.
The back has a noticable hump attached to it. The Hump has 3/16th inch pin stripping details placed on it, and at atimes the was 4 horizontal bars present on the upper left side of the hump. The "promotional" costume had a grey square in place of the horizontal bars. See the Reference Pictures section for pinstripping placement.
You'll want to refer to our plaster casting and vacuumforming sections to make the final vacuumformed armor parts.
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