First, the pattern was drafted by covering the cosplayer in plastic wrap and then tape, drawing out where the armor would fall across the back, chest, and then arm. The tape and plastic pattern is then cut out, and transferred onto fun foam and Worbla.
The foam is then sandwiched between the Worbla sheets for stability. Each piece is layered together following the pattern. The spine is attached by strips of elastic that are glued into the underside of the panels with more Worbla. This lets the spine move and sway while still holding the shape. D-rings are added to the bracers for strapping that will keep them closed.
The mask is a great example of layering Worbla. The frame was made separate from the eyes and mouth, then attached. Then the forehead and lower jaw were attached, with layers of Worbla adding more depth and detail. Finally, a large sheet was heated and draped over the entire form to even out the layers but keep the depth, making a seamless but 3-dimensional mask.
More details including the creation of the staff, formed by carefully molding pieces of Worbla over carved Styrofoam. Be warned you can’t use a heat gun on Styrofoam directly! It will melt! Instead heat your pieces separately and then add them to your form. Then everything was primed, then painted.
Saviours Hide/Hircine from Elder Scrollsby Pipa Wolf won Judges Choice at the MCM Manchester Comic Con
I made a mold of my body using gaffer tape, then drew on the rough shape of my armour, which I then cut out and transferred the pattern onto foam sheets. (The foam sheets were later sandwiched inside the armor for strength)
Here are some pieces with the foam sandwiched inside, before and after fusing the Worbla layers:
I then adjusted the shape until it resembled the base shape I desired.
I then added accents using the Worbla; any leftover pieces were molded into studs, spikes and rings.
Priming the armor:
Painting the base coat and weathering the bodice.
The leg armor in progress.
Leg armor with spikes and fur added.
Leg Armor, painted and weathered.
The finished leg armor.
The finished costume:
The Worbla was really easy to work with and I’m really happy with the end result, it was my first try at making armour and using Worbla and I’ve had incredible feedback from fellow cosplayers. It has actually encouraged a lot of people I know to get into cosplaying and making bigger projects.