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  1. Hey everyone! (I apologize if this should go into the Tutorials section but since this is specifically for Revan I thought I should post it here!) My name is Rachel but I go by my artist name, NightShine!! I am a shameless nerd whose favorite thing to obsess over is – you guessed it – Star Wars! But even better than that is STAR WARS COSTUMES *whaaaaat*!! I’ve been cosplaying for a little over two years now and as of January 2016 joined the 501st ranks with my Darth Revan. The concept for Revan’s outfit has always been a particular favorite of mine and, being the artist-nut I am, decided to make my own Revan entirely from scratch! Upon my researching and building I, for some reason, couldn’t find information on how to make Revan’s mid-section armor to save my life. I had made a temporary one out of an Allergan air filter (lol) which didn’t look half bad but I knew that I would need to replace it sooner or later. Thankfully, I had made some amazing Mando Mercs friends, one of who was an excellent seamstress. She shared her knowledge with me on how I could go about making Revan’s mid-section armor and I set out to accomplish the task! This brings me to my post – I want to share my mid-section armor build knowledge in hopes that someone out there, who is having as hard of a time figuring this out as I did, could find it useful. There is also, obviously, more than one right way about making this – this was just how I made mine. I also just like making tutorials. Here we go!!! 1 - To start, I had purchased a black vinyl fabric from Joann's and cut it to *roughly* the size I knew I'd want it to be (PLZ PLZ PLZ always cut MORE fabric for stuff like this - unless you're working directly from a pattern - because it's easier to cut off excess fabric than to put fabric back on!!). 2 - Folding the fabric in half, I lined up, pinned, and sewed (one at a time) tiny foam noodles (Caulksav'r Poly-Foam Backer Rod 5/8 in (D) x 20 ft (L) brand name Dennis). You will need to use a zipper foot for this part (reference in picture 8, left side). I just sewed a simple straight line - nothing fancy for this part! 3 - The ridges are starting to come together! NOTE* I am using the zipper foot here - this particular sewing foot comes in handy when you want to sew directly up against an edge without going over it -- just make sure your needle has been moved ALL THE WAY over to the left or right (depending on which way you're sewing) or that needle will snap right off on your presser foot lol is scary 4 - Cut the excess fabric from the edges and started pinning the bottom (well, shown at the top here) excess to cleanly seal it off. 5 - Bottom is sewn to perfection and is ready to go! I used a combo of zig-zag stitching (to first seal off the visible, cut edges) and straight-line stitching (to hold down the fabric when it was folded over for a cleaner look). 6. Cut out excess foam lining (about 1 inch in my case) on each end to make room to sew the attachment parts onto, or you could just make sure in step 2 to have plenty of extra fabric on the end – your choice!
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