I've been researching how to do the rubber armor, I figure these are the steps necessary (extremely abbreviated).
1. Create a copy of your torso (using whatever method you'd like, there are several), cast a dummy form duplicating your torso to work on.
2. Sculpt clay on the dummy torso to the contours and details of the armor ( also, have the talent to scupt or this step won't work, my personal problem, will have to learn on the job :lol ) The armor isn't all that thick from what I can tell. so the clay won't be either,. Also, if your doing this, you can modify the details to your advantage, like making the channels match the width of your el tape exactly so you won't have to trim.
3. Create a mold from sculptured clay armor, using latex that you brush on to the clay.
4. Use that latex mold to cast the rubber armor.
5. Install el tape, wire it up.
6. Head out to the grid for DISC WAR! :cool
Something like this
http://www.smooth-on.com/gallery.php?galleryid=393
Anyone with more knowledge on the subject, I'd love to hear your input, am I on the right track?
Ultimate method:
Smoking hot Sirens walk out and hook you up with your armor and disc. :love