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Making Armour

Making Armour

What do I have for you this time?

Charmender’s newbie guide to making armour, featuring the amazing AmenoKitarou (A.K. Wirru).

I have tried to make armour. If you have seen my Fairy Tail’s Erza Scarlet in Purgatory, then you know I tried to make the shin guards, and also know they didn’t work so well.

AmenoKitarou (A.K. Wirru) at Supanova

AmenoKitarou (A.K. Wirru) at Supanova

So , instead, I’m talking to a pro on how to make armour, and make it well.

What was the first armoured cosplay you made?
I think it was Woodrow Kelvin from Tales of Destiny.

Now that you have more knowledge, how would you make it differently?
I think I would’ve reinforced the foam a little more. It was really soft.

What are the items you need to make some armour?
I like using PVC plastic. It’s cheap and light.

Where can you get these materials from?
I normally buy plastic from Reverse Garbage in Marrickville.

Is making the armour an expensive part of cosplay to get into?
I am good at budgeting my armour materials so armoured characters are cheaper for me than sewing.

Is there any simple character designs a newbie should try to build up their confidence?
Armour is everywhere in game designs. Maybe look at some simpler characters from some JRPG games.

Check out AmenoKitarou’s Facebook page for more amazing cosplays.

AmenoKitarou out!

AmenoKitarou out!


  • Start working on your armour long before you need it so that, if there are any hiccups, they can be worked out easily and there is no rush. With rushing comes mistakes.

  • Mistakes are good. They will help you learn and improve. You will get poopy it didn’t work out, but you will walk away with the knowledge of how to make it better, and what not to do.

  • Try and start with easy patterns without much detail. Don’t go jumping in to make that Diablo armour just yet. Also start with cheap materials so if there is a mistake it can be fixed or remade cheaply.


To make it easier to start out I found some Youtube tutorials on how to make basic stuff.

Baby steps guys, baby steps.

Quick foam armour tutorial using craft foam.

A longer tutorial, using EVA foam.

A pauldrons (shoulder guard) tutorial with EVA foam.

Charmender's Erza Armour

Charmender in Erza Armour

Here is one of the only pictures of me (Charmender) in my Erza Armour.
Its made from foam and paper mache, nothing fancy. I am looking at remaking it with warbla and getting some pictures done.

Finally I need credit my best friend ShadowWolf for making Erza with me and RiotArms for my beautiful baby sword.

Enjoy and Peace out!
– Charmender.

About sparksman

Apparently my name sounds like a superhero. Geek. Gamer. Knows far too much about some topics because of work, but isn't dead yet.

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