Away from a medieval armoury, Aldeus armours owe more to polyester resins than metal alloys.

Thanks to the first shoot's tight schedule, the original armours were realised in record time. Starting from scratch, a skeleton special effects crew sculpted, moulded, cast, sanded and finalised five complete armours (21 pieces each) in less than 3 weeks. Photos taken during the process are shown below.

Since then, an updated design has been developed, with prototypes made using alternative techniques.



 

Wrapping the model with plastic film, prior to plaster moulding.

 

Suggestions for intrepid souls considering DIY armour-making:

· Avoid painful accidents! All safety regulations pertaining to the chemicals and resins used must be carefully followed.

· For those with little experience, books on plaster-moulding of the human body can be helpful in covering the basics and providing safety guidelines.

· Making a full body armour will cost about US$500 in materials, provided every piece made is a success the first time around. Starting with a more modest endeavour, such as a helmet, is probably a good idea.

· Those living near Paris (France) will be able to find the products needed for armour-making at: Polyester 93, Zac Ariel Building, 2 24 av. Henri Barbusse, 93012 Bobigny Cedex. Tel : 01 48 44 55 74.

The mould is used as a base on which armour pieces are sculpted using clay.
A sculpted helmet made of clay, ready to be moulded.
A mix of resin and fiberglass is used for the moulds.
Armour pieces cast from the moulds. The metallic finish is created by mixing black gel coat with aluminium powder. Several layers of resin and fibreglass are applied to strengthen each piece.
Once dry, each piece is carefully sanded. Final steps include polishing, binding, fitting.