I based how I did things using Volpin's methods, who based his off Evil FX's. Both did amazing jobs, so I highly recommend checking them out. As a warning, I took these pics with my phone, so they aren't the best quality. I have a friend who needs lots of photographs for a class, so I'll have pics to post from a photoshoot with her later.
First up, the medium!
Did I happen to mention it's cheap? No? Okay. Well it's cheap!
I didn't make my own pattern, mostly because I don't have paper rolls handy yet. I used one from Ithica, found on the 405th.com forums. It was a pretty basic pattern, admittedly, but considering how much time I had I didn't want to get too fancy. After completing it I can tell you every problem it has, but I was more concerned about getting it done in the meantime.
First I assembled the arms:
In the meantime, I used my trusty dremel and sanded down key spots:
I assembled those, swapping a couple more detail pieces with craft foam, then shaped it using the oven (no heat gun yet - taxes soon!).
I used the same foam for this and, though it didn't turn out 100% the way I wanted, it still turned out pretty friggin' awesome. I used another simple template: same forum, from GeneticSpartan. Here's the rundown:
Of course, during all this the straps came in, so I was working on both about halfway through the pistol. Here's me strapping the chest and back together:
And now, for the final shots! I only need to burn in some small details on the shoulders and add a strap to the biceps, but besides that the pistol and armor are complete!