I used two displacement "filters" or modifiers as we call them in Blender and later applied car body filler in a way that supports this bumpy, imperfect texture. Same thing with powder.
Fixing hinges - the big one is v1 for which I was hoping to use hole spots from the original game model which was dedicated for laces. Sadly those would not work due to alignment issues so I made this hinge/locking pin solution similar to what I have on the sides
V2 - now I can round the corners, give it a bit more beat up look with hammer/metal tools and then maybe treat it with acid to make it look more like the armor.
Side locks WIP - also a bit custom solution in comparison to the game model, but the original one would not even physically work so this is as close as I can get. Thought about making it two sided in each section but it's a lot of extra work that would not provide any additional security.
I might do it anyway later since it would look nice, for now it's enough. Those holes a bit more spread apart are for leather laces.
Oh man, it's been a while... Recently got myself a dedicated workshop which finally allows me to have a proper space for prop making. When it comes to Alexios - I'm working on the final version of hinge locking system. Here you can compare old and temporary with the almost finished stuff + some step by step picture
Another update - lower hinges are not as tightly packed as the top ones which I will later fix but for now I just want to get those copper sheet parts ready. Also waiting for copper rivets to arrive from China (for some reason they were hard to get in my country).
Only need to add those small rivets and I can start sculpting battle damage. Fun fact for those who never played the game - those shields were not available for the player. Only NPC warriors had them so in a way I'm fixing this weird error of playing a shieldless spartan