HOWTO: Making Metal Alloy Jango Armour

  1. #1

    Member Since
    Jun 2009
    From
    Newcastle NSW Australia
    Posts
    137

    HOWTO: Making Metal Alloy Jango Armour

    I needed a break from the Westers I'm working on so I thought I'd tackle having a go of the armour and pop up a bit of a tut on how I'm doing it.

    This may hopefully help out some other Jangos hoping to make their own alloy armour.

    Firstly here is the belly piece, cut from 2mm alloy

    dsc02283-jpg

    Now I've taken a piece of 15mm (I think) steel and filed a round edge they I need to 'fold' the alloy over.

    dsc02284-jpg

    Then mount it in the vice were you can see the filed curve

    dsc02285-jpg

    Then sit the alloy over the edge of the steal by a couple mm

    dsc02286-jpg

    Then take the flat of a ball pen hammer and hammer an angle about 5-7mm all the way around the edge, this will allow the piece to look thicker and have more light curve on the edges of the alloy armour (Will make more sense later, stick with me!)


    you can see here the hammer marks, this is the face side up
    dsc02290-jpg

    on the underside you should have something like this

    dsc02289-jpgdsc02287-jpg


    Now comes to the curving part

    I managed to pickup a piece of PVC from work that was 25mm X 200mm, I found this was perfect for all the armour panels

    dsc02296-jpg

    also wrapped an old tea towel around it to help stop any sharp dints accuring in the armour

    dsc02297-jpg
    now start hammering away, use about 50% of what you would use to hammer a nail in some hard wood.

    dsc02299-jpgdsc02298-jpg

    now ending up with something like this

    dsc02301-jpgdsc02300-jpg

    now get the files out and clean up the edge that has been hit with the hammer
    dsc02302-jpgdsc02304-jpg

    Now you need to file a 45 degree around the edge of the whole panel

    dsc02305-jpgdsc02306-jpg

    Now use a smooth file and clean up 'round' all the work you've done so far

    dsc02308-jpg

    use 240grit - 400 - 600 - 800 - 0000 steel wool - 0000 steel wool and polish - cloth and polish

    and here you go

    dsc02314-jpgdsc02313-jpgdsc02311-jpg


    here is a bit of a before and after on the shoulder pieces using the same technique

    dsc02292-jpgdsc02293-jpgdsc02295-jpgdsc02294-jpg

    A couple of chest shots

    dsc02270-jpgdsc02259-jpgdsc02257-jpg

    and here is where I am at so far, I'm very happy with the way they are coming up!

    dsc02316-jpg
    Last edited by Werstrooper; Oct 5, 2010 at 9:22 PM.

  2. #2
    Tracyn Ordo's Avatar
    Member Since
    Nov 2008
    From
    New Zealand
    Posts
    86

    Re: HOWTO: Making Metal Alloy Jango Armour

    Looking impressive!
    Just out of interest, how are you intending to create the detailing on the right chest piece?

  3. #3

    Member Since
    Jun 2009
    From
    Newcastle NSW Australia
    Posts
    137

    Re: HOWTO: Making Metal Alloy Jango Armour

    good question, still havent made up my mind. it will be one of two ways

    1) Dremel out the indentation and have a rough surface finish inside the step

    2) drill and file out the indentation completly, and then mount a thinner piece of alloy inside the cutout, this way it's nice and clean.


    i'm thinking the latter, only thing is it's much more work

  4. #4

    Member Since
    Apr 2008
    Posts
    1,792

    Re: HOWTO: Making Metal Alloy Jango Armour

    this is great looking armour do you mind telling me what u used to cut out the metal with? i tryed this once and it did not work out well at all.

  5. #5
    Revan's Avatar
    Member Since
    Sep 2010
    From
    Bristol UK
    Posts
    30

    Re: HOWTO: Making Metal Alloy Jango Armour

    jinto said: View Post
    this is great looking armour do you mind telling me what u used to cut out the metal with? i tryed this once and it did not work out well at all.
    I cut my 2mm Aluminium armor plate with a hack-saw. Then tidyed up the edges with needle files.


  6. #6

    Member Since
    Jun 2009
    From
    Newcastle NSW Australia
    Posts
    137

    Re: HOWTO: Making Metal Alloy Jango Armour

    jinto said: View Post
    this is great looking armour do you mind telling me what u used to cut out the metal with? i tryed this once and it did not work out well at all.
    I used a band-saw and a guillotine

    if you didnt have access to something like that then the method Reven used would be your best bet

  7. #7

    Member Since
    Jul 2011
    From
    sylvania,Ohio
    Posts
    1

    Re: HOWTO: Making Metal Alloy Jango Armour

    do you think sheet metal would work?

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