1. Member Since
    Jul 2003
    Sep 2, 2008, 4:37 PM - Samurai Armor #1

    I have a little spare time and was thinking of making some samurai (like from movie Last Samurai) armor out of composite materials. I have some carbon fiber/kevlar stuff, which I thought would make some kickass armor ( I have red/black, yellow/black and blue/black see sample below).

    However I am not as experienced, talanted or skilled as many on TDH site.

    I was thinking of starting with cardboard, then fiberglassing over it then using the carbonfiber/kevlar as the top layer. Then spray with clearcoat, then sand to class A finish (being careful not to damage the cloth.

    alternative method would be to make cardboard plugs, then fiberglass molds then lay the carbonfiber/kevlar in them for a class A Finish.

    any thoughts or suggestions?

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  3. Member Since
    Jul 2003
    Sep 6, 2008, 7:05 PM - Re: Samurai Armor #2

    Progress report

    I made some cardboard molds, and tried to pull some casts from them they worked good for the first pull, but then started to get tore up on the second pull.

    I think I am going to make some cardboard plugs then create fiberglass mold then use that to pull the casts. Will be more durable.

    I also experimented with different material to save money. I am using paper towels in some of the layers in stead of the glass. I use it on the back layer and it gives a smoother surface then the glass.

    The first picture shows the cardboard molds I had created. they are a negative shape from the final.

    The next picture is of the plates I got off the molds, the longer one will be for the SODE (arm armor).

    On the second pull of the plates I used starting with the outer surface layer, paper towel, glass mat, papertowel, glass mat, paper towel.
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  4. Sep 6, 2008, 7:15 PM - Re: Samurai Armor #3

    If you want to build Samurai armor check out this site

    They have patterns and some great info. However if you want to build some get your hands on some plastic barrels. I currently have a suit made from one.
  5. Member Since
    Jul 2003
    Sep 6, 2008, 9:57 PM - Re: Samurai Armor #4

    Thanks for the info.

    I am familiar with Anthony Bryant's site on samurai armor. I am using some of the information from there. However I am doing a display piece and will be borrowing from his site as well as what has been done for the movies for dramatic effect, not authenticity.

    I liked your plastic barrel suit. I had seen a site which describes how to make one. But again for display purposes, I decided to use fiberglass, and will give it a smooth finish, and can do custom form fitting where necessary. Nice job lacing the haidate (if that is your armor in the picture you sent).

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