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
Now I've taken a piece of 15mm (I think) steel and filed a round edge they I need to 'fold' the alloy over.
Then mount it in the vice were you can see the filed curve
Then sit the alloy over the edge of the steal by a couple mm
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
on the underside you should have something like this
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
also wrapped an old tea towel around it to help stop any sharp dints accuring in the armour
now start hammering away, use about 50% of what you would use to hammer a nail in some hard wood.
now ending up with something like this
now get the files out and clean up the edge that has been hit with the hammer
Now you need to file a 45 degree around the edge of the whole panel
Now use a smooth file and clean up 'round' all the work you've done so far
use 240grit - 400 - 600 - 800 - 0000 steel wool - 0000 steel wool and polish - cloth and polish
and here you go
here is a bit of a before and after on the shoulder pieces using the same technique
A couple of chest shots
and here is where I am at so far, I'm very happy with the way they are coming up!