The Samus Aran DIY Project: Pauldrons
So let’s just get right into it. Here is the Pauldrons tutorial.
Materials:
2 foam balls (10”+) found in the floral department of your local craft store
Old newspaper (no glossy magazine paper though)
Elmer’s Glue
EVA foam
Bronze acrylic paint
Black acrylic paint
Masking tape
Measuring Tape
4 screws
Large knife (be VERY careful with this/ get adult supervision!!)
Toothpick and string
Instructions:
1. Unwrap foam balls and prop up on solid surface (I used a vase so I could still turn it)
2. Start by drawing a line around the center of the ball (a), then another perpendicular (b). The points where they intersect will give you the center on each side of the ball (c). Measure the distance between the center points and mark the center of that length on each side (d). Now mark the point ½ the distance between points (c) and (d) on both sides to give you point (e). To get nice, even lines around your sphere, place the toothpick in the foam at point (d) and tie one end of the string to a marker and the other to the toothpick. Make sure the marker end of the string is tight at point (e), and then draw a circle. Do this on both sides and we will call them lines (e). Below is a diagram (not perfect but hey, it helps to visualize!) of your template markers.
3. Once you have your template, draw on the shape of the pauldrons how you want them to look. Here is mine:
4. Using the large knife, cut out the area marked with arrows. BE VERY CAREFUL using the knife, I almost cut my finger off…literally blood everywhere. It’s hard to cut through this foam and very messy, so make sure you lay down a drop cloth of some sort for easier cleanup. Anyway, I made flat cuts, fitting the balls onto my shoulder several times to see how to cut them out in order to make them sit comfortably. As you can see, I did this step after the paper mache, but you can really do it either way. I switched the steps only because I accidentally cut into the newspaper and had to repair it, so I figured it might be easier to cut first, mache later.
*HINT: measure between lines (e) for your foam wing cutouts BEFORE you paper mache. Also, if you have more time, you can chisel out lines (e) and (a) to give more dimension and possibly a place for battery powered green LED string lights. I would have done this if I had more time, but the costume was already extremely time-consuming, so I just painted on black lines in the end.
5. Now make some Paper Mache mix out of 1:1 Elmer’s and water. Tear newspaper into strips, and dip into mixture, making sure to squeegee off the excess. Paper Mache the entire surface, including the cut out section. Repeat for at least 2 layers, and be sure to let dry completely between each layer to avoid molding. I did 4 layers.
6. You can cut out your foam pieces while the spheres dry (I initially wrote “while your balls dry” but thought better of it. *Ornery giggles ensued*) I measured between lines (e) earlier and cut an arch to fit (x4). Once your paper mache is hard, tape down the wings where you want them.
7. PAINT! Using the bronze acrylic, cover the entire pauldrons except the cut out, which you will paint black. Add details and DAMAGE!
8. Finally, once all the paint is dry, you may be wondering, HOW DO I ATTACH THESE THINGS?! Once your entire costume is ready and you are getting all the pieces on, screw 2 screws up through the shoulders of your vest (tutorial to come, worry not!!) and into the pauldrons.
That’s it! Hope you enjoyed this tutorial. Stay tuned for the next installment in
The Samus Aran DIY Project: Leg and Boot Armor.