Today i began work on the chest piece of armour, loosely following instructions from
this forum post.
I will be using this foam to create a back piece, and will add details later on by cutting the shapes i want raised out of a different piece (of this foam) and gluing them down.
Measuring and detailing the sizes needed, from my waist up to my shoulder and then down my back to my waist again, then around my waist and chest, i cut out a square piece that ended up as around 20 inches by 48 inches.
From here i cut a hole in the centre of the piece large enough to fit my head through and sit comfortable on my shoulders. It is a rough cut, especially at the back, but this hole will be covered in the final piece by the coat and neck guard.
After this i made some more measurements and cut indents on either side for my arms to fit in. These turned out to be a little too small, so judging mostly by eye i trimmed them down some more, especially at the back, to allow more mobility of the arms. again, this part is scruffy looking but will be covered up by the coat (or, can be tidied up at a later date if need be.)
This is the piece as it is now, the bottom held being the back (with the square arm holes) and the top being the front piece (rounded arm holes.)
I am a little on the fence about having the whole thing as one piece, and may choose to replace the back with elastic straps further down the road. if not, however, the foam will be worn like a poncho and the sides then buckled together to hold in place.
A lot of work is to be done, and hopefully at the weekend i will have a chance to continue working on it, perhaps even finishing. Firstly i have to cut out armour details to be glued on, and will be using this as a reference:

Once cut out, i will sand the edges slightly to give it a more realistic look, then glue the pieces down onto the base i have. after this i will add the neck guard, which is thicker and i may use a different foam for, depending how it turns out. once the pieces are all together, i will spray paint the entire piece with a base layer of black, then cover the gaps between the armoured pieces with tape before spraying the armour again with dark grey. once the colour itself is done, i will apply stencils to the chest area, and finally use a soldering iron to add battle damage to the armour to make it look worn, as well as lightly sanding the stencils to give them a faded look. Finally i will touch up any paint where needed, such as the battle damage, and then it should be complete.
These are, roughly, the images that will be adjusted to make the stencils (as both are fairly complicated for a block image stencil.)