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my shin guard progress NEW PICS

Discussion on my shin guard progress NEW PICS within the Zam Wesell Costume forum, part of the Star Wars Prequel Trilogy Bounty Hunters category; Can you believe it? For those of you who I've

  1. #1
    MonCal's Avatar
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    my shin guard progress NEW PICS

    Can you believe it? For those of you who I've told I was working on this I've finally got something to show The sculpt is still quite crude but I've begun working on it again. This is just the overall shape / outline. I'll begin adding the border and circle detail on the bottom as soon as I'm satisfied with the shape. Enjoy





    cal

    Edit: Scroll down for updates

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    Dustin Crops Boy's Avatar
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    Re: my shin guard progress

    YEAH! Love it so far Gonna vac form 'em or glass¿ I'm pretty sure the originals are vac'd w/ leather over that. - but i could be wrong.

  3. #3
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    Re: my shin guard progress

    Woohoo!!!! looks awesome. what did you use? Clay on top of a mannequin? Cause that is definately some nice work. Have you decided how you are going to do the back calf side where there are three (straps? hooks?)

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    Dustin Crops Boy's Avatar
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    Re: my shin guard progress

    the back has just 3 standard black snaps - nothing more, nothing less.

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    Re: my shin guard progress

    Thanks guys!!


    Dustin Crops Boy wrote:

    the back has just 3 standard black snaps - nothing more, nothing less.
    Great!! that's what I was planning. Do you have an idea about the size and style of snap? All I have to go off of are the action figures.

    I put all the rest of the detail around the bottom this afternoon. I still need to smooth the whole thing out. I'll get some more pics up hopefully in a couple days.

    Zam I Am, this past summer (sheesh talk about slow) I made a mold of my wife's leg and cast a plaster leg to work off of. I recently used the length of the pistol to scale the rest and had to modify my sculpt althouth it is really close to what I had started way back when.

    Dallas, after looking at the pics you took especially the ones that you can see inside the guard from underneath (numbers 4232 and 4235) I am under the impression that it is made from a slush mold. It looks a lot like the inside of my royal guard helmet. When looking at the large image of 4235, I can see the rough shape of the inside of the circle piece. Infact, that is what I plan to do. I want to make it out of a similiar material. I want to make it so it will flex a little but still be quite durable. I still haven't nailed down the products yet. Also as you mentioned, it does look like it has a leather texture to it. I have been planning to texture the sculpt with leather or a stamp made from leather prior to making the mold. I'm hoping this will work like patching vinyl with a stamp. If that doesn't turn out, a lightweight leather could be wetformed to it.

    cal

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    Re: my shin guard progress

    I added the bottom details today. Here are some more pics




    cal

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    Re: my shin guard progress

    Moncal are the added bottom portons raised or indented. it is hard to tell from your pictures, but I know from the MOM shots dallas took they all appear to be raised. Just thought I would point that out if you had indented them.

  8. #8
    Dustin Crops Boy's Avatar
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    Re: my shin guard progress

    well - they're definetly leather covered... you can see this clearly in some of the pix - especially down by her shoes - where you can see the leather edge rolled under the edge of the shin.

    The snaps are standard black Dritz™ snaps you can get at any fabric store - the kind that are 4 parts.

  9. #9
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    Re: my shin guard progress

    Ragresen, yes they're raised sorry if it's a bit of an illusion.

    Dallas, I think you're absolutely correct! It is very evident in your pic #4235. Inside what would be her right shin, it looks like the leather has come unstuck and the rough edge is clearly visible. I suppose the top was too pointy to do the same detail as the bottom so they edged the top with a strip of leather .

    Another thing I just noticed in your pic #4232 again on her right shin, it looks like they spaced the shin from the foot guard where they bolt together with a piece of white cloth. Not that that's necessary but interesting anyway

    cal

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    Re: my shin guard progress

    After talking with the rep. at smooth-on, I think I have the plastic material figured out. I just need to figure volume, order the stuff and hopefully be able to get a positive casting Then onto forming some leather


    cal

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    Re: my shin guard progress

    I ordered the casting materials today. I'll post an update as soon as I have a casting! yeah..on to the next step

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    Re: my shin guard progress

    I have lookedd over the pictures mentioned and even at others and I am not convienced that they are leather covered. I say that because you would see soem form of wrinling on some of the edges if it was and that part that was mentions on the inside I see nothing there at all that says it is an endge of leather. I see an area that looks like light hitting the inside different, but it is too blurred to tell what it is. Also I recommend they be done in fiberglass or vaccume molded as they will need to be flexable to get in and out of them.

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    Zam I Am's Avatar
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    Re: my shin guard progress

    Moncal, fiberglass right?

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    Dustin Crops Boy's Avatar
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    Re: my shin guard progress

    i have seen MANY pix that prove your wrong, ragresen

    Oh, and i saw it in person too They ARE leather covered.

  15. #15
    Zam I Am's Avatar
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    Re: my shin guard progress

    What kinda leather do you suggest? That guard sure is smooth. I mean, I don't see any leather grains. Any proposals on getting them so freakin smooth?

  16. #16
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    Re: my shin guard progress

    I am going to make them similiar to how a Royal Guard helmet is made. From looking at the pics DCB took, the inside of the shin guard looks pretty much the same as the inside of my RG helmet. At any rate, After previously asking about this stuff over at the RPF and then talking with the rep at smooth-on, I've ordered a plastic material that I can do a slush mold and it will be semi-rigid and somewhat flexible at the same time. With the way I am planning to do the snaps on the back, it will unsnap, flex enough to slide a foot through and flex back and snap. I haven't received the material yet..I hoped it would have been here by today. I'll know more after I make a casting as to how it will react. I would hope to have the material and give it a go in the next few days.

    As for the leather, perhaps we can work together on figuring the best material for the job. I don't have the luxury of talking with a knowledgeable leather salesmen here locally as I live in a ski resort community thus, few suppliers of such things. (smiles real big)...Perhaps zam i am can take her standup back to the leather shop and ask about that one too
    Ragresen,
    I wasn't 100% convinced at first either but after DCB pointed it out, it was very apparant to me. I always thought it had a leather texture to it but wasn't sure. The first real clue for me was the trim on the top edge. The second was inside the bottom of her right guard, the leather looks like it has come unstuck. The line that shows the edge of the plastic underneath fades away at the same point the leather fold inside appears to be leaning out. Tough to explain

    EDIT: Here is the pic I was trying to explain sorry I should've done this first!

    The arrows show the area I believe the leather has come unstuck and is leaning out, it's also sort of frayed.
    Here is the pic of the other side:

    And here's one of the top edge. Both the trim and main surface look to be a leather texture and the trim appears to be sort of creased out at the point, which led me to believe that it was a leather trim around the top edge..


    until next time
    cal
    Last edited by MonCal; 01-20-2005 at 06:03 PM.

  17. #17
    Zam I Am's Avatar
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    Re: my shin guard progress

    I have a 501 thing to go to this weekend, so mebbe next weekend. I still have to get my tandy catalog first. Moncal, did you get a catalog? There might tandy store near you, they are all over the US. I will try and ask the guy, but I am not crazy about this whole natural leather idea (for the skirt). It's very high maintenance. I don't want to have to worry about "treating" and conditioning the leather every year. I can understand repairs if damaged, but not high maintenance. Same idea would apply for shin gaurds for dyeable leather. I can't imaging having to do that for all the leather parts. Yuck. The guy offered some help, but he got busy with customers. I work 2 jobs, so I can only see the guy on Saturdays before 2pm to ask him questions.

  18. #18
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    Re: my shin guard progress

    If it's leather, and you get some softer stuff, you should be able to give the shin a layer of rubber cement, and tightly stretch the leather over the surface.
    As for the shirt Zam, don't worry about conditioning. Unless you plan on hanging it out in the middle of the desert, in the wind, it won't be a problem. There's a product that they make that you just wipe onto the back of the leather, and it'll keep it from cracking up. No, not that cracking up...
    But this stuff is mainly used to restore old leather, like old military belts, ect.

  19. #19
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    Re: my shin guard progress

    Sith,
    Is it similiar to saddle-soap? for softening old leather?

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    Re: my shin guard progress

    OK. Here's the way this works:

    1. Wetform the leather (2-3 ounce max) to the piece and let it dry. Make sure to get the edges rolled over the plastic or whatever and clamp them to the inside. DO not allow the clamp to touch the exposed areas that will be visible. When it is completely dry, peel the leather away and it will have the shape. Apply contact cement to the shin guard and the leather, let it get tacky, and the press together carefully smnoothing as you go. The contact cement will make the leather slightly moldable just enough to move it around a little against the surface. This is how I did it for CEL 2 and it is still holding up. Recommend Barge for the contact cement. Very good stuff.

  21. #21
    MonCal's Avatar
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    Re: my shin guard progress

    O.k.,
    I've finally got a little more settled in my new home, am learning my way around my new pc, and am able to work on this again
    Here's the first casting fresh out of the mold:
    Sorry they're a little blurry!


    I've got to refine my process a bit as it's a little thin in spots but I believe it's going to work
    I'll post more when I've got it cut. I think I'm going to make a plaster casting to shape the leather to. Now I need to go find the leather.
    Last edited by MonCal; 01-20-2005 at 06:05 PM.

  22. #22
    Admin Staff MaulMaus's Avatar
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    Re: my shin guard progress

    Yeah... I still see the boxes in the background! Moving is just no fun!

    The casts are looking great though! Nice work!

  23. #23
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    Re: my shin guard progress

    Thanks for the compliment!!
    Yeah, I should take pictures of other rooms...wait, there aren't any rooms..just tunnels through mounds of boxes and that's for real! This place is just temporary...it's so much smaller than my house that we moved from uggh

  24. #24
    Zam I Am's Avatar
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    Re: my shin guard progress

    Looks great, so, you are going to try to wet form it after making another cast? Or, are you gonna sand/drill/dremel the legs out?

  25. #25
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    Re: my shin guard progress

    I'm thinking about making a plaster "master" and wetform the leather to it since it'll be solid. The formed leather should fit the castings. I was originally planning to wetform to the casting but since it's hollow and flexible, I don't think it'll be rigid enough to stretch leather against.

  26. #26
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    Re: my shin guard progress

    Some more progress and a quest for opinions
    The first plastic casting trimmed and next to the plaster cast: These pics look worse (blurry) here than they do on my pc for some reason.




    Now my question. I have had a plan to cut the back with a couple ideas to do the snaps and overlapping. I still need to play with those ideas if I end up cutting them. The thing is, my wife can slip the thing on and off with no problem. I can almost get it on and my foot is a 12. I could leave it solid and attach the snaps for looks after it's wrapped with leather. There would be a seam in the leather in the back.
    Although my original plan might also aid in slight adjustments to size if someone had a calf that was a little tight. What do ya think?

    Speaking of adjustments, if someone was short and the guards are a little out of proportion, they could be trimmed down a little on the top.

  27. #27
    Zam I Am's Avatar
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    Re: my shin guard progress

    Dang, those look sweeet!!! so, if you cut them in the back, how pliable are they to bend around for real snaps?

  28. #28
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    Re: my shin guard progress

    They're fairly bend-able..similiar to my Don Post Boba Fett helmet... maybe a little more flexible. I'm extremely pleased it turned out exactly as I had hoped!
    I would do a normal snap setup like a jacket might have rather than a button setup so it would just overlap and snap to the piece underneath. That's what I had planned but I was wondering about opinions since my wife can slip it on and I actually can too since I tried (it's pretty tight on me though)

  29. #29
    Zam I Am's Avatar
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    Re: my shin guard progress

    I just don't know how you would fake a seam if you don't cut it. And, um... Please don't get mad at me or throw darts,I hate to ask you this after, but... you dont have a lip at the very top of the shins. I guess a solution would be to glue lace on top, or add an edge of putty or sumthin. I think that cutting it might be the way to go instead of a fake back, but i don't see how it's possible to not cut it, and still have a seam. ya know?

    oh, size/measurements please? can you measure the tip of the top front to the bottom, and the back of the gaurd to the bottom and also the width of the calf? Thanks. That will help determine weather or not it would be wise to cut it down the back.

  30. #30
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    Re: my shin guard progress

    The top edge has always appeared to me to be a leather edging. That's what tipped me off to the leather at the very beginning when I was having doubts. I'll have to cut a strip of leather and form it to the edge and glue it. It can be wider in the back and go down inside to have more resiliance. This will also be helpful if someone wants to cut it down if they're very short...I don't think anyone of us here is that short anyway

    I agree with you about cutting the back. That was my plan originally. If you notice on the picture of the back side, the lip at the bottom meets and begins to go up the back but stops right where the curve ends. This is so I can cut it on either side of that lip and round it for either the right or left leg. That would be the overlapping side of the guard. The leather strip on top would then come down the edge and meet that lip. On the underlapping side, I will make an extension to go under far enough for snaps and the leather will wrap around it and come back on the inside of the guard past the joint. The overlapping side will overlap the joint a little and I'll sand the lip on the underlapping side to where they meet....hope that makes sense.

    I'm not sure what measurements you want exactly. It's the same measurements we were discussing a couple months ago...Here's what I think you're asking:
    Front, tip to bottom(top of shoe area).......11 5/8"
    Top to bottom in the back...................7 1/4"
    Width halfway up,front to back..............4 5/8"

    I wish we weren't so far apart, you could look at it in person..I'm tempted to send it to you..but you have to send it back..it's basically the prototype

    Thanks for the input!
    Cal

  31. #31
    Zam I Am's Avatar
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    Re: my shin guard progress

    Where do you live now that you've moved? Mebbe we can meet halfway . I would love to have a zam Prop meeting at my house b4 d'con, that would be AWESOME, like in July. But we know that's not gonna happen. Now that you've moved, are you closer to a tandy?

    Mebbe it's just me, but view askew-- the stand up has her one foot forward. Proportionally, is that larger than a real person's shin or ...? Can you take a pic with wifey's leg in the cast? That would give us a better idea of looks especially of the right leg in it, kinda like the stand up.
    Actually, I was hoping for the total width by the ankle and the total width from just under the calf all the way around. Let me snap some shots of the leather that I have. Mebbe it Might work if you got the same stuff. I could totally be wrong though. I haven't dyed or cut any of my leather that has been ordered, cause I want to be able to return it if it's not the right type. I know my skirt is ok, but shins -- is more your territory, you've stared at the pics longer than me
    First is the MOM pic, second pic (I think it looks better with extra leather or putty underneath the thin leather then wetformed or just glued than the third pic, third pic = lace on top


    These are just thin leather pics. I really think the skivers are it, and just need to be dyed.

  32. #32
    MonCal's Avatar
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    Re: my shin guard progress

    Hmm..
    I was originally going to sculpt the edge on top but there is a picture of the mom shin about halfway up this thread that shows the tip of the guard. The leather trim is creased out on the very point. That was the pic that made me decide to do it that way. I'll have to look but I think there is another one that Dallas took that shows a similar camera angle. Either way, I can't change my molds now..about $400 in em plus many months

    The leather trim on the top edge could be one size thicker than the rest of the leather..?
    When I first scaled the guard, I used the length of the pistol and enlarged the pic in the VD where she is kneeling until the gun was about 1/4" smaller than it really is. This is because the guard is fairly square to the camera and the gun is a little bit behind her leg. Later, I purchased the stand up and the guard is the same size as the enlarged pic that I made. I'll try to get some pics with it on my wife's leg.

    I'm still in Colorado..just closer to Denver. A Tandy store just opened up in Denver about 3 weeks ago.
    I'll also work on some dimensions to show you

    cal

    edit: here are some more pics:


    Please remember she is 5'2" so her leg is a little short. The guard is also translucent so it's tough to see the details in these pics also with lighting and angles etc...
    Last edited by MonCal; 01-20-2005 at 05:21 PM.

  33. #33
    Zam I Am's Avatar
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    Re: my shin guard progress

    I think i understand about the leather now. My guess is a .5" piece of 1 - 2 oz. leather wetformed onto the tip of the shingaurd all the way around back. And the shingaurd covered with the skivers underneath. Just a guess. I already spent $300 in leather. Some of it was wrong, some of it is right. I am not an expert by any stretch, but I did cut up three hides already. There is a remarkable difference when you cut different hides and realize their thickness. If you enlarge/shrink my top pic to the size of hers, you will see how thick the trim should be. (I think it's pic 04238 ) And I am not talking about how wide of a cut. For 1-2 oz leather, that's about 1/32" thickness max, like the skirt lace.
    Measureing off of the cutout, i get .25" width on the frontside for the trim, so I can only assume it's that much on the back.
    Hope this makes sense. I think on page 10 of the tandy catalog, you'll get what i mean.
    btw, if you send it to me (zam i am might slink away tip toe-ing hoarding your shin gaurds, never letting you see them again..)

  34. #34
    Jaster Mereel's Avatar
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    Re: my shin guard progress

    I just love WIP pics, awesome job your doing!

  35. #35
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    Re: my shin guard progress

    Thanks Jaster!
    I do to

  36. #36
    Zam I Am's Avatar
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    Re: my shin guard progress

    For Moncal,
    Sith C, wookie, mebbe you can answer this...
    Do you think that a 1 oz. trim is just wet formed and placed atop the skivers (rather than a plastic indented "lip" sculpted, then thin skivers, just wetformed/shaped to the "lip" and the whole shin gaurd) ? Or am i totally off? Anyone with any some leather expertise, please share...

  37. #37

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    Re: my shin guard progress

    Sorry:

    I haven't been studying the pics like you guys have, so I can't offer much in the way of advice. True, you could just wetform a piece to get the lip and achieve the look in that photo you attached (Zam I am). I'd have to do a lot of studying before I'd say what I thought they did, and it is very likely that I'd be wrong. For minor details like these, I've seen where LFL cuts corners because it will never be seen in the final print or even on display, so I venture to say that if you find the easiset method, you will probably have it.

    I will continue to lurk and watch as you guys perfect the zam costume. Looking sharp I might add. Dallas' helmet is approaching perfection (I knew he'd do that when I first talked to him about the costume and he told me that he'd never have it done for Cel II because he couldn't get it right). I was more than happy with mine.

    Oh well. See you guys. My latest projects call me. My Nightcrawler is coming along nicely...

  38. #38
    Zam I Am's Avatar
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    Re: my shin guard progress

    BTW, process goes- wetform, dye/paint, then glue, right?

  39. #39

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    Re: my shin guard progress

    Glue comes last. The other two can be done at the same time if you wish (use the due to wet down the leather if you thin it enough). I prefer to wetform and then dye. The guy who taught me switches techniques.

  40. #40
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    Re: my shin guard progress

    NIGHTCRAWLER?!?!?! Let's see some pics of that!!!

  41. #41

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    Re: my shin guard progress

    I've got 'til Halloween to finish Nightcrawler. No pictures yet.

    Contacts ordered.
    Makeup mixed
    Scars figured out
    Hands done
    Teeth done
    Ears in progress
    Clothes on the drawing board
    Tail internals started
    Tail sculpt started

    Teleportation in process

  42. #42
    MonCal's Avatar
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    Re: my shin guard progress

    I actually found another tandy dealer near me. I went and waisted about an hour of his time yesterday
    The leather for the shins is so thin, it doesn't need to be wetformed. We played with wrapping the guard with the dry leather and it actually took the shape remarkably well. He had some that was purple but it was way too "grapey" or I would have wrapped that guard already.
    He was pretty sure the top edge was a leather trim also but said if we (the group ) decided it isn't, we could glue a strip of leather on the top and form the skiver over it. I'll run to the other Tandy dealer and get a second opinion...hopefully tomorrow.

  43. #43
    MonCal's Avatar
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    Re: my shin guard progress

    I've had a couple inquiries regarding dimensions. Here's a pic with a couple. If others are needed, I can add them.



    BTW, are my pics showing up for everyone?



    cal
    Last edited by MonCal; 01-20-2005 at 05:22 PM.

  44. #44

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    Re: my shin guard progress

    i can see them
    Zam

  45. #45
    MonCal's Avatar
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    Re: my shin guard progress

    good! thanks

    It seams my hosting service isn't totally reliable so I ran a few through the TDH service (Thanks for the service!!!)

    I'll have to experiment but here's a theory proposed by 3 different leather shops on the leather edge:



    The leather would probably glue down, a series of holes would be punched through both pieces of leather and the plastic. Stitching would go through the holes. the leather would be glued, folded back over itself and glued to the inside of the guard.


    cal
    Last edited by MonCal; 01-20-2005 at 06:08 PM.

  46. #46
    Admin Staff MaulMaus's Avatar
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    Re: my shin guard progress

    How big would the holes be? Looks about right for the top of the shin guard... but what about where the guard attaches to the "metal" piece that rests on the boot. (I don't know what any of these pieces are supposed to be called... ) Is the leather just glued down over that rounded area?

  47. #47
    Zam I Am's Avatar
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    Re: my shin guard progress

    I don't understand the "stitching" I mean, if you glue it down, that should hold everything. I don't remember seeing any "stitching" I would just putty the top edge or put bondo on it to make a lip, then wrap the whole thing with that "lip" and just make sure you have a groove for the leather to fit exactly with the glue. Crease it with the end of a knife or some other tool.

  48. #48
    MonCal's Avatar
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    Re: my shin guard progress

    The holes wouldn't have to be very big...enough for the thread. I think the glue would be necessary to force it more flat. If it was just stitched, it might not stay as flat. This is just for the top edge. The bottom edge is sculpted and leather formed over it.

    Zam i am, you would stitch the piece down then fold it back over itself covering the stitching. This would force the edging to have a tight distinct line like the orig. and help keep it from coming undone. I think these will be too flexible for bondo anyway. If you want to overlap a sculpted edge, you could attach a strip of leather to the top edge and form over it. It's tough to explain ...much easier to show in person. Again, this is just a theory and I'll have to play around with it. Probably can use the same leather as the rest of the guard because it'll be folded over itself.

  49. #49
    Zam I Am's Avatar
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    Re: my shin guard progress

    Okie, here's my quickie sculpt and rendition. Which wouldn't require any odd overlapping, but same effect methinks. AND no stitching, just glueing. Drilling tons of little holes through plastic is not my idea of fun... That's just like punching the holes for the skirt imho, but worse...
    Anycow pic one is a quickie sculpt of what you have. Then add on the bondo lip (mine is all sculpey, but you get the picture).

    Then just glue all under that thin leather and use a tool to make sure it's in tucked into that "creavace" to make sure it has a good "lip" look.


    yay or nay?
    Oh BTW, I have never used bondo before, so wet formed leather would do nicely in replacement (as you pointed out)I assume too much (I think everything is as pliable as sculpey..)

  50. #50
    MonCal's Avatar
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    Re: my shin guard progress

    Here's a "real" pic of my fancy illustration above only not sewn.




    of course the suede side would be in and the edge wouldn't be black
    Drilling would be easy with the dremel..only take about a minute or so...then lay the strip of leather on top and thread it, fold and glue. I could pre-drill it anyway. The needle would easily thread through the leather. Again, I need to try it first
    Last edited by MonCal; 01-20-2005 at 06:11 PM.

  51. #51
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    Re: my shin guard progress

    is that black piece weather stripping? so you would make it two pieces of leather? that goes on top of weather stripping?

  52. #52
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    Re: my shin guard progress


    Zam I Am wrote:

    is that black piece weather stripping? so you would make it two pieces of leather? that goes on top of weather stripping?
    ??
    I'm confused..sorry. It's just another piece of leather (pig I think) that happens to be black. It's folded just like my drawing above. The lavender piece ends just like in the pic at the edge of the guard. Another piece of leather (the black in the pic) will sew on, fold over itself and glue. I think it's impossible to have a formed edge and try to cover the whole thing especially at the point. It will wrinkle itself and won't be smooth. It would have to combine too many sharp corners..

  53. #53
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    Re: my shin guard progress

    ooops, ok, then you are going to use three pieces of leather, i see. I kinda understand the stiching, it would be hidden. Hmmm. Very interesting. That works too. I thought you could just angle cut it on the back side to prevent wrinkling and use all one piece.

    The things that make you go hmmmmmm....

  54. #54
    MonCal's Avatar
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    Re: my shin guard progress

    Two pieces of leather:
    1. The lavender piece in the pic which will cover the entire shin guard.

    2. A strip of leather cut to maybe 2" to cover the top edge.

    Hmmmm

  55. #55
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    Re: my shin guard progress

    what about that black piece? isn't that going to be #3 leather piece?
    hmmm?

  56. #56

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    Re: my shin guard progress


    Zam I Am wrote:

    Anycow pic one is a quickie sculpt of what you have.
    Why are u bringing up cows at a time like this?:p
    last time i checked we were discussing shinguards.
    Then again, leather is from cows.....hmmm.....
    btw, Dallas, what the heck is that thing on your avatare?
    it looks like a mutated greedo!:p
    no offense zam i am!!!:p j/k
    ZamWessel~

  57. #57
    MonCal's Avatar
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    Re: my shin guard progress

    The piece of leather I used in the pic to show how to do the top edge just happened to be black to help show contrast as will the white leather below. I will use either another piece of lavender or white and paint it along with painting / weathering the whole thing.

    Step one: cover the entire guard with a piece of leather (lavender in the pic) cut even with top edge. It will form to all the details on the bottom edge and can be glued. These pics are just set up as an example. The real deal will be trimmed and fit the entire guard.


    Step two: cut a piece of leather approx 1 1/2" wide that is the length of the entire top of guard (including going down the backside overlap).


    Step three: Sew the leather to the plastic guard with stitching approx. 3/16 from the edge and fold over (glue as well). Glue it to itself and to the inside of the guard.


    Step four: The edge is complete. Paint / weather the entire thing. Two pieces of leather.
    Last edited by MonCal; 01-20-2005 at 05:30 PM.

  58. #58
    MonCal's Avatar
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    Re: my shin guard progress

    Finally have some more progress
    Still need to do some trimming on the shoe guard, add the top edge, and weather it of course



    (These pics don't really do justice since the net seems to blur them up a bit)

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    Re: my shin guard progress

    wow!!!!moncal that looks awesome!!!!!!!!your definately the one im going to for tips when i make my shinguards!!

  60. #60
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    Re: my shin guard progress

    thanks zamwessel~ !

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    Re: my shin guard progress

    n/p, i only tell the truth!!!

  62. #62
    Zam I Am's Avatar
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    Re: my shin guard progress

    Like the famousse words of paula abdul... WOOoooawwww!
    Sweet!

  63. #63
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    Re: my shin guard progress

    Thanks Z.I.A. !
    Man you were up late last night

    Did some mods on the shoe guard:


  64. #64
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    Re: my shin guard progress

    Yeah, umm...
    I was up late...
    um...
    cause I was fooling with....

    192 zam skirt squares!!!

    I laced half of the skirt last night Man it is a major pain when your lacing needle just gets clogged and you have to do the rest with L shaped pliers! And, thank God I have a mother in law who sewed my red veil tonite. Hey-- you were up pretty late too!
    Nifty ankle gaurds, man you are working things out really awesome! I haven't looked at any shots for critiques, but Looks great to me

  65. #65
    MonCal's Avatar
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    Re: my shin guard progress

    Thanks!
    Yeah I was up late as usual but trying to make some progress on these guards. I want to move on to another part of the costume

    Lacing needle? Can ya show me one?

    Here's some more pics....top trim and snaps:




    Now to bust out the airbrush

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    Re: my shin guard progress

    Thats really looking awesome so far moncal!!

  67. #67
    Zam I Am's Avatar
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    Re: my shin guard progress

    Is the back of the shins with a leather fold over too or is that just sculpted, and leather layed on top? And where did you stop with the fold over so that it ends? at the bottom point of the round joint? I havent had time yet to do the whole pic thing with the skirt. I was hoping to do it when I was finished lacing the whole thing with pliers.

  68. #68
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    Re: my shin guard progress

    Thanks for the kind words!

    The leather trim on the top edge continues down the back side and butts to the sculpted edge just at the top of the curve. I abruptly stopped the sculpted edge just as it rounded that corner so that I would have a place to end the folded trim. This first attempt is pretty good but I think I can trim it to blend much better next time and then with airbrushed highlights in and around the crevace, it will hopefully blend even better.

    It's a little tricky getting the leather trim piece to round those corners although not so bad once I figured it out. I had to glue it first part way up the edge, sew it up until about an inch from the corner, stretch it over the corner (while folded) and get the leather worked out a bit, glue the edge around the corner and stick the leather while folded, let it dry, unfold, stitch, and refold. (if that makes sense )

  69. #69
    Admin Staff MaulMaus's Avatar
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    Re: my shin guard progress

    Those are awesome shin guards!!! Wow!!!!

    Thanks for sharing with us how you did all the work too!! Now.. to apply what I've learned!!! *Like buying a few extra lacing needles! *

  70. #70

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    Re: my shin guard progress

    I think your work on the shin guards is great and very well done.

    I have some questions on your process to get there.

    1. how did you get the clay for the original sculpture so smooth? I have tried projects like this but have had trouble getting it smooth.

    2. You then made a mold which allowed you to make a plaster cast as well as a slush cast. Can you explain that process, including materials used?

    I have been struggeling with projects like this maybe your expertise can help.

  71. #71
    MonCal's Avatar
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    Re: my shin guard progress

    pastafett wrote:
    I think your work on the shin guards is great and very well done.
    Thanks very much for the kind words!!
    Quote:
    I have some questions on your process to get there.

    1. how did you get the clay for the original sculpture so smooth? I have tried projects like this but have had trouble getting it smooth.
    Actually, the clay didn't come out as smooth as I would have liked. Since it gets wrapped with leather and the plastic casting can be sanded, I decided it was good enough which worked out just fine. If it wasn't going to be wrapped in leather, I would've done a cheaper mold with a plaster cast then sanded the plaster and made the actual urethane rubber mold from that. I just made a plaster cast to have a back up solid cast.
    Quote:
    2. You then made a mold which allowed you to make a plaster cast as well as a slush cast. Can you explain that process, including materials used?
    I used a urethane rubber from smooth-on. I simply made a box a couple inches bigger than my sculpture in every direction, built up a halfway point with clay around the sculpture while lying on its side. I then poured the rubber in for one half, flipped it over when cured to pour the second half. I will say, this isn't a very lucrative process. With the cost of clay, rubber compound and then the urethane plastic compound for casting, I have close to $400.00 invested just in getting a few sets of guards. This doesn't include the leather, snaps, etc. Now that price wouldn't necessarily influence the cost of one set of guards but just the cost of making the molds. A set of guards would be a fraction of that cost



    To do a casting, I had to make this "spit" for the mold. I had to rotate this progressively slower for 1 1/2 hours to allow the casting compound to form a hollow shell.

    After 16 hours, I then could demold it and spend another couple hours with a dremel trimming off the excess and finishing.
    Last edited by MonCal; 01-20-2005 at 05:35 PM.

  72. #72
    Zam I Am's Avatar
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    Re: my shin guard progress

    All i can say is WOW wait.. where's the drop the jaw on the floor smiley?

  73. #73
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    Re: my shin guard progress

    Dedication or insanity?

    Regardless... they look just fantastic!!! The quality shows in the amount of work you've done on these! Wow!!!

  74. #74
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    Re: my shin guard progress


    MaulMaus wrote:

    Dedication or insanity?

    Regardless... they look just fantastic!!! The quality shows in the amount of work you've done on these! Wow!!!
    Hmmm..? dedication...insanity...dedication....whichever it is, as always with this hobby I'm learning new things which in itself is rewarding Thanks for the positive comments!

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    Re: my shin guard progress

    YOUR WORK REALY LOOKS GREAT AND I THINK IT WOULD BE GREAT THAT YOU ARE WILLING TO SELL A PAIR.
    I THINK THE COST OF THE MOLDS WOULD INDEED BE THE MOST EXPENSIVE THING TO MAKE.
    I LIVE IN HOLLAND AND I'M MAKING A SUIT FOR MY GIRLFRIEND&AND ANOTHER FRIEND.(SO I NEED 2 PAIR)
    I KNOW IT IS A LOT OF WORK TO MAKE THESE PARTS I'M WORKING ON MY HELMET AND UNDERSUIT.
    THANK ANYWAY FOR SHARING YOU WORK.

    GREETINGS JEROEN.

  76. #76

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    Re: my shin guard progress

    Yeah, I'm that friend, but even if you're willing to sell a pair, how much would it cost and are you sure that they'll fit on everyone?

  77. #77
    MonCal's Avatar
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    Re: my shin guard progress

    Thanks for the interest! I haven't decided on a finished estimate yet because I still haven't worked on the weathering, etc. Most of the cost will be for materials as they're not really cheap. I can figure an estimate for them in kit form though.
    Yes, they can and will fit just about anyone. They're flexible and I can adjust them for overlap. I will need a measurement though. As in the pics below, I'll need a measurement around the lower calf at 9 1/2" up from the heel as marked by the piece of masking tape on her leg :




    As you can see, my wife's lower calf measures 12" around. I mainly need this measurement to ensure enough room for overlap and if I need to pour extensions on the guard.

    Please send me a pm to discuss more details


    cal
    Last edited by MonCal; 01-20-2005 at 05:39 PM.

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    Re: my shin guard progress

    (hello,
    thanks for your reply i didn't saw your pictures of your progress work but i have a new internet connection and i must say WOW! i measured my girlfriend's leg and she has the same size so that's perfect.
    my friend Gaeriel comes with measures soon.

    thanks jeroen&saskia.

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    Re: my shin guard progress

    I'm about the same size, just over 12,6"

  80. #80
    Zam I Am's Avatar
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    Re: my shin guard progress

    BTW, all, Moncal's shins are sooo cool. They are NOT made outta fiberglass really... The material he is using is perfect for putting it on and taking it off the leg. It's not rigid like vacuumformed plastic. You'd all be amazed. In hotter weather it is more flexible, and cooler weather, it's a tad more rigid. BUT! it keeps it's memory and doesnt ever lose details i.e. those rounded joint parts at the base of the shin. I must say, superb sculpt, and his anklegaurds are also just as awesome. He even made it longer on one side. There is a right side and left side anklegaurd. I didn't even notice till I got em. Really good eye there matee
    I wrapped my own leather with glue and I put my own styrene top "lip edge" on his gaurds, cause I didn't want to feel around, poking myself to get the "lip" effect by the leather only like Moncal did. Both methods work, his might be a tad nicer when it comes to overlapping leather problems at the very tip top angle point below the knee. My pieces of leather, actually from Dallas, was really stretchy, and that helps, especially when glueing down things and trying to eliminate bubbles and also becuase the shell is rounded, but with different widths. If it was perfectly cylindrical, you could achieve perfect and easy glueing, but shin shells aren't, so the leather being stretchy helps out tremendously. I also learned to start glueing from the front center out, otherwise, you could run out of leather.
    Now, when you wear them, you should consider going to the fabric store and getting adequate foam for the inside of the shin. This is needed to lift the shin up a little, because the top of your ankle will hurt like the dickens with styrene and the shins digging into the top of your ankle. Comfort first, those joints do move, but don't stay, so, foam it somehow ESPECIALLY if you do a parade or con or something.
    Moncal , way up for the shins!

  81. #81
    MonCal's Avatar
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    Re: my shin guard progress

    Thanks for the positive review Yvonne!!

    I'm really happy they worked out well for you. You were pretty much the trial run on these things And any advice for improvements or mods is very much appreciated!!!

    I don't know for sure yet but I doubt they'll dig into a persons' ankles with the regular prada boot underneath since it goes up the leg a ways. Also, I bet if I drill the hole out a little more for the bolt that holds the ankle guards on and the nylon locking nut is used but not tightened down completely, they'll move more freely. Also, maybe putting a cloth spacer between the two might help..( remember seeing that in one of the MOM pics).
    Wish I could get our suit done and put it to practical use so I would know for sure

    thanks again,
    Cal


  82. #82
    Raef_Wolfe
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    Re: my shin guard progress

    What are the metalic round circles in the back of Zam's shinguards and over the ankles? They look like brass fasteners, similar to those below.

    <img src=http://images.officemax.com/images/kreb_large/09015442.GIF>

    Would these work? And what are the fasteners for, really? Me wanting to save as much money as possible is looking for inexpensive solutions :p

  83. #83
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    Re: my shin guard progress

    Awesome thread!

  84. #84
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    Re: my shin guard progress


    Raef_Wolfe wrote:

    What are the metalic round circles in the back of Zam's shinguards and over the ankles? They look like brass fasteners, similar to those below.
    Well, the shin guard actually overlaps itself in the back and snaps together with typical dritz snaps...found at tandy. The plastic allows this with its flexiblity. It is rigid but also flexible at the same time unlike typical vac-formed ABS or even fiberglass.
    There are screws on the sides of the guards that bolt the shin guard to the ankle guard.

    Seeker, thanks!!

    BTW,
    I am back home, although things are still chaotic I have been making some progress



  85. #85
    MonCal's Avatar
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    Re: my shin guard progress

    Finally able to make more progress. Apologies to those patiently awaiting completion!!







    EDIT 12/11/03:
    Here are some pics with the flash....quite the color change still blurry on the net though




    Edit 1/20/05: fixin pics
    Last edited by MonCal; 01-20-2005 at 05:53 PM.

  86. #86
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    Re: my shin guard progress

    WOW Big color difference there. So which one is it more like? The leather color of the top more-red, or bottom pic-more lavender?

    VERRY excellent resilient shins btw. I still think they are sooo awesome. Especially cause you picked out the right casting materials. I hear troopers complain all the time about breaking/cracking pieces of their costume. I have no remorse when the shins I have from ya, take a beating. My remorse comes from everything else I've have that isn't shatter proof and I have wound up with MORE putty and MORE paint on everything. I spend more time on repairs than on upgrades. Nothing likes to just stay resilient cept for your shins! I think I have lost my toe spikes the most~ 2-3 times already.

    Keep up the great work!

    Yvonne


  87. #87
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    Re: my shin guard progress


    Zam I Am wrote:

    WOW Big color difference there. So which one is it more like? The leather color of the top more-red, or bottom pic-more lavender?

    Thanks zamiam! I'm glad you're still happy with them.

    Well, the real color is closer to the top 5 pics which is the lighter color and closer to the pics in the Visual Dictionary. I just thought I'd show the pics with the flash to show how much variation there can be with different lighting


  88. #88
    MonCal's Avatar
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    Re: my shin guard progress NEW PICS

    Just fixin pics

  89. #89
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    Re: my shin guard progress NEW PICS

    Oops found the right thread now! yay. What sort of glue did you guys use to glue the leather down with onto the shins? Im gonna try these this week Were we using the skins for the veil on this or dyed skivers?

  90. #90
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    Re: my shin guard progress NEW PICS

    if i remember correctly cal stated he had some alternative method for the shins...cal? any luck on that

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    Re: my shin guard progress NEW PICS

    Righty dokey! I just enquired about some sheepskin skivers for the shins, what dye did you use to dye them with Moncal? I thought about using the back of the veil pigskin but its not the right color and ive spend a month getting the front the right color LOL

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    Re: my shin guard progress NEW PICS

    These shin guards are nothing short of AMAZING. Fantastic work.

  93. #93
    I helped at SDCC '08 GCNgamer128's Avatar
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    Re: my shin guard progress NEW PICS

    Great job! Very impressive

  94. #94
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    Re: my shin guard progress NEW PICS

    Ok scratch getting the skivers They want £44 for one 12 foot skin for me to dye myself and im not paying that!!!

  95. #95
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    Re: my shin guard progress NEW PICS

    Quote Originally Posted by Langsuir666 View Post
    Ok scratch getting the skivers They want £44 for one 12 foot skin for me to dye myself and im not paying that!!!
    12 feet? Do you even need that much for the shins?

  96. #96
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    Re: my shin guard progress NEW PICS

    They will only sell it in whole skins which is approx 12 feet Im not sure how much we need

  97. #97
    I helped at SDCC '08 The Clayster's Avatar
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    Re: my shin guard progress NEW PICS

    That is pure awesomness

  98. #98
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    Re: my shin guard progress NEW PICS

    becky, i know at the tandy i went to they had some real cheap pigskins...6 dollars a piece...thats whay i used to make the test pattern for our vest...the leather is a little dark but they had some lighter stuff as well...if your going to paint the shins rather than dye i bet that stuff would work and its real thin and inexpensive...some pieces have some bad spots on them but if your going for the worn and weary zam...then that shouldnt be an issue

  99. #99
    Admin Staff MaulMaus's Avatar
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    Re: my shin guard progress NEW PICS

    Tandy didn't sell the skivers last time I tried to get some. I think the cheap stuff you're talking about is way too thick (it looked like that from photos of the vest).

    Well... one alternative is the Vogue leather pelts http://www.voguefabricsstore.com/sto...p-1-c-296.html The skins are very very thin (and soft!) and would work well for covering the shin guards. You would need one skin per shin guard (I measured on mine and it would work fine.).

    The only issue might be color - the "Dusty Lavender" that I had bought was a bit dark - I don't know about the regular "Lavender" as I never bought any. I bought a "natural" one recently, but it was suede on both sides (much more on one than the other) You could dye it the color you want - but it wouldn't look as shiny as you might want.

  100. #100
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    Re: my shin guard progress NEW PICS

    Quote Originally Posted by MaulMaus View Post
    Tandy didn't sell the skivers last time I tried to get some. I think the cheap stuff you're talking about is way too thick (it looked like that from photos of the vest).

    Well... one alternative is the Vogue leather pelts http://www.voguefabricsstore.com/sto...p-1-c-296.html The skins are very very thin (and soft!) and would work well for covering the shin guards. You would need one skin per shin guard (I measured on mine and it would work fine.).

    The only issue might be color - the "Dusty Lavender" that I had bought was a bit dark - I don't know about the regular "Lavender" as I never bought any. I bought a "natural" one recently, but it was suede on both sides (much more on one than the other) You could dye it the color you want - but it wouldn't look as shiny as you might want.
    So was the Dusty Lavender one shiny on one side? Or suede on both like the natural?

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