Today was all about getting the mid-section of the armour to fit. I fibreglassed the inside, then drew a line where I want to cut it for fitting. I used a couple of plastic wall-plugs wrapped in paper to make seating pins and poured resin mixed with car-body filler over them. I then cut them apart, pulled the cut wall-plugs out and installed new full-length ones. One end will be glued in, while the other end will serve as a guide-pin when getting dressed.
1. Wall-plugs covered in paper and tape. A block taped off to form a dam where the casting will be poured.
2. Cast poured
3. Cut the armour apart with a hacksaw, straight across the middle of the pins.
4. To get the pins out, I used a wood-screw, screwed it in part way then pulled out the plugs.
5. Now both halves fit together perfectly, lined up by the guide pins.
6. It fits! I might have to go for a run or two though, this mid-section is starting to getting a little bloated underneath...
