Boba Fett 2 Gauntlets

I took some time over the weekend to make up some forms for shaping the pvc expanded cell board for the gauntlet base pieces.  There are curved pieces that wrap over the top and bottom of the forearm that have a bunch of stuff attached on top.  Wizard of Flight has some curve guides for them.  I transfered the curves onto some pieces of plywood, cut them out, mounted them, and then wrapped them with some card stock.

Then I cut out some pieces of board slightly oversize to the plans.  When you heat this stuff up, it tends to get some irregularities and curving at the edges.  So I figure I'll get the curve in there and then cut them to size, square them up on the belt sander, and clean them up.  That way I can be sure to cut the piece from the section that has the right curve.  I got a big pot of water to a full boil, then I dropped the pieces in one at a time.  It only takes 30 seconds or a minute for them to get floppy.  Then with some gloves, I put the pieces over the form and shape them down to fit.  As soon as it cools, it holds the shape:

Cool, huh?  Don't worry.  These are oversized on purpose, and they are supposed to have some slightly different shapes for the assemblies that attach on top.  

I got to thinking about these after I made them.  These are 1/8" thick.  There's another piece that double over the tops of these with some cut outs.  So that'll be 1'4" thick total.  That's too thick and cumbersome, I think.  So I found some 3/32" thick stock in my pile in the garage.  As soon as I have time, I'll redo this in the thinner stuff.  Eventually these will be painted and weathered to look like they are metal underneath.