This is the pattern I used for making the Lightning's pauldron The four pieces are DOWNLOADABLE in separate files in a larger resolution.
I will also try to explain some things here, but this is not a step-by-step guide to make the pauldron. It needs previous knowledge about craft foam usage and it is rather an insight into how I made it, for your inspiration, needing your own creativity to finish it, should you decide to use the pattern.
(Pieces are numbered in the downloadable file)
The first piece is the main armor body. The lighter raised parts are drawn there so you know where to place them. I made this from 3mm thick craft foam. Redraw this on the craft foam two times - once for the main body, once for the outline. The outline is roughly 5mm wide so it is easy to draw it around by guesstimate.
The second piece is for the lighter raised parts. The pattern goes with the outline to stick them together, but cut both parts apart when on the craft foam. I made this with 2mm thick craft foam.
The third piece is for the crest-piece of the armor. Follow what I said for the piece one.
The fourth piece is the pattern for the straps. I made these from a light leather, later colored using the same colors as for the whole armor.
Once you have everything cut out from the craft foam, just glue the outlines on the body pieces and the raised part onto where it belongs. When dry, shape the whole thing under heat (I usually use oven for this). A lot of foam will be spare with nowhere to go, so try to accumulate it onto the back part. After the first round of shaping, cut out the lines in red on the main body piece and glue the sides together, you should get rid of the spare foam that way. Do a second round shaping after drying and you should have the perfect shaped armor.
*A hint: I used a pomelo to help me shape the foam - it had a perfect shape, round but not too much round (and was edible later
). Also a melone or a big orange can be used for the shaping. The actual shoulder is not good because it is not round, having bones structure and all.*
I included some WIP shots though I do not have many. For the crest, I printed the shape (I found a vectorized EPS of the crest together with some other useful info here on this forum: [link]
I used the EPS but modified it a bit because it was inaccurate, having an arrow instead of a leaf on the right side). After printing in the desired size, I glued it onto a piece of a craft foam and cut out an inversed version of it as seen on the WIP shot (I removed the glued paper after cutting). I imprinted this stamp into another piece of a craft foam (3 mm thick): I used iron to make it hot, then I attached the stamp to it and pressed it for few seconds (I used a book and my own weight to do this), until the hot craft foam got normal temperature again. The result was a piece of a craft foam with the crest relief on. I took this piece, drew the outline of the full armor piece (as seen in the patterns) around it, glued the outline piece to it and shaped it a bit after drying. I use iron again to do this, even though I usually use oven for craft shaping. It is because the crest relief disappears easily when hot. So I just ironed it for a second on the BACK SIDE and shaped it round.
The imprinted shape is without the "Cocoon Army" writing (written in Coccoon letters). I added this later on using the 3D Lack (a glue-like thingy that holds its form after drying). I missed a letter there but I hope nobody will actually notice....