Hi Thomas, I don't know if you remember me, but I wore Kyle Katarn for CIV. I am attempting to create a Rahm Kota for D*C08 and CV. I have never done any sculpting, mold-making, or casting, and there were a couple of things about your described process that elude me.
Re: Step 1 above, what did you use to reinforce your duct-tape mannequin (DTM) so it would hold shape while you applied the clay for the armor plates?
Did you plaster-cast the whole shebang while the clay was still on the DTM?
Re: Step 4, what are "mold walls?"
Many thanks for your help, Maestro. I am being driven, albeit slowly and methodically, into new crafting territory by this costume...
~ Bill Costigan