- 1). Measure the width and height of your chest. Draw the shape of the chest piece onto a foam board, making the armor as wide and long as your chest. Make sure to leave a scoop shape for your neck. Divide the chest piece into about eight vertical pieces. Samurai armor is made up of a series of slats. Make an identical piece for the backplate. However, do not make a scoop for the neck in the back piece.
- 2). Measure the width of your side. Cut the same number of slats for the side pieces as you did for the front. Make a scoop shape in the top piece for your arm to fit through.
- 3). Cut two shoulder straps to hold the front and back pieces together. Measure your arm from shoulder to elbow. Cut one long piece of poster board to match this measurement. Perforate the armor into three sections so the armor bends slightly. Cut four square pieces to add to the bottom of the armor for lower torso protection.
- 4). Cut the chest piece out and cut the slats apart with a utility knife. Draw six small holes on each vertical edge of each slat with three holes to each row. Draw three more rows of three holes each spaced evenly between each piece. Use a hole punch to punch out the holes.
- 5). Punch holes in the edges of all other pieces in a similar pattern. Remember that all of the pieces must fit together for the armor to work properly.
- 6). Paint the slats with your chosen paint color. Allow to dry for at least two hours.
- 7). Weave a long piece of ribbon through the holes along one side of the chest piece to hold the slats together. The slats should overlap slightly. Use a second piece of ribbon for the other edge, and a single long piece to weave the middle portion together. The weave you use is not important, as long as the slats stay together.
- 8). Repeat this process for the remainder of the slats. Tie the front and back pieces to the side pieces with nylon rope. Tie the shoulder straps in place with rope, then tie the arm pieces to the shoulder straps with the rope. Finally, add the bottom pieces to the armor.
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