The armour was created using 2 different methods. For the gauntlets. the main hand and finger parts were 3D printed flat shapes which I then heat formed. I used superglue on the inside of the hand part ridges to hold them in shape while I gently heated and shaped them to ensure they fit together properly. As my 3D design skills have now improved, I would probably have 3D printed them already in shape, but that wasn't an option back then!
The wrist was made with an EVA foam base, covered in worbla, this was to provide comfort while wearing.
The finger plates were superglued on to a pair of tight leather gloves, I wanted to make sure that they were tight to give as much dexterity as possible to add to the creepiness.
All of the foot armour was made with a single sheet of Worbla, heat shaped and attached with screws, the shins were created like the wrists, with an EVA foam base covered in worbla.
The whole lot was airbrushed in a metallic silver, and then accented in rust, to give the decayed look.
The last step was the weapons. I used the hilt for the sword from an online file, and modelled my own blade in order to accept a wooden rod on teh inside for strength. The handle for both the sword and the Morgul blade were wrapped in real leather, the blades were painted with a silver rub 'n' buff.
The scabbards were made with EVA foam, wrapped in thin cardboard, wrapped in real leather, this gave them structure, but also protected the blades from being scratched. These were then attached to a real leather belt with buckles bought from Germany made of wrought iron.