DARTH VADER ARMOR

Once again, we made Darth Vader's armor from PVC-Sintra. Although there are only five pieces when finished, the Darth Vader armor is the hardest armor to make, as it requires a lot of gluing and clamping of the various pieces. We started by making patterns of the armor based on the pictures in the Star Wars Visual Dictionary. Then we traced them onto the Sintra, and cut them out using a Jigsaw. We attached the various layers with epoxy. We finish-sanded the pieces after drying, then spray painted them with Rustoleum Engine Block Black paint, which has a shiny finish.

The entire process takes about five days. But if you're patient and do it right, you'll have an authentic suit of Darth Vader armor.

To see the finished Darth Vader costume, visit the Darth Vader Gallery.

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