well, what i did was buy some sheets of the sintra, and made my self some templates out of cardboard, and posterboard. i then just traced the templates onto the sintra, and cut the out with an Xacto knife. i then took my peices to my oven, and preheated it up to 350. i then took a cooking sheet, and placed 1 peice at a time placed them into the oven onto the cooking sheet. i then just watched it carefully. i would open the oven every once and awhile, and would kinda bend the plastic to see it it was flexable. as soon as it got soft, i took it out, and curved it accross my chest. make sure you have about 2 shirts on, or an undershirt, and a Tshirt. 
i basically got my general shape of the armor. i then ran the peice under some cold water. that helps it set better. and then, you repete the process. don't let the armor get so soft that it is like paper flinsy. for the battle damage, its nice to have a dremel tool. i just carved out all the battle damage with one.
michael
