Well my registration didn't go through over at the Prop Den, so I figured that I'd post this here. I'm currently putting together an ANH Vader costume for Halloween, the trick is I need it to be a lot tougher than normal. This costume will be meant for fast paced heavy deuling, and the last thing I want to do is shell out hundreds of dollars on fiberglass and plastic/resin parts to have them destroyed in combat. So, enter the idea of steel. I've done a small bit of traditional armor smithing in the past, so I thought why not try this with Vader.
The tools I'm using are very basic:
Forming tools (reshaped railroad spikes, ball hitches, etc.)
And not so basic:
And here is the initial work that has been done on the chest armor. These pieces won't be exactly screen accurate, but they will be near enough to look good.
As you can see, it is still in the rough hammer work phase, and lacking the outer ridges. Due to the limitations of the material (more likely my limitations in skill) the ridge lines might not be as crisp as on a fiberglass casting.
I will also be doing the belt boxes, chest box, and remaining armor in steel. If time permits I also have a low quality cast of a 20th Century face mask that I'll be smithing a steel dome for.
Here is the start of one of the belt boxes. Just tack welded at this point.
And here we have the chest armor in a quick spray of black to see how it looks under my new Darth Stone helmet.
If you guys have any qustions or comments I'd love to hear them.