
I thought I would be fun to show, step-by-step, the process that I went through to build my “Duke” armor. Mind you, I am a creative, but by no means a costume designer nor a seamster. So work with me.

Oh, and by the way, I have also designed my wife’s gun holsters for her costume. She got off easy; I bought her costume at Party City. The holsters will be covered in another tutorial.

Items you will need:
- Hot glue gun
- Spray glue
- 1 can silver spray paint
- 1 can black spray paint
- Sewing machine or a needle & thread (add about 40 more hours!)
- Ruler
- Blue Painter’s tape (wide)
- Self-healing mat
- 4 yards black fabric
- 4 yards green fabric foam
- 1 roll of black craft foam
- 2 sheets of thick black craft foam
- Cardboard (for patterns)
- Sharpie
- White fabric chalk
- 2 yards velcro
- 4 yards black belt strap
- 4 yards black elastic
- 2 side release backpack buckles
Total price for materials: $87.00
Total hours worked: 30ish?
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