The Do
PLEASE NOTE -- Because this is the first section on pattern making and assembly, I'm going to go into some detail of how to design and build the armor. For all of the remaining sections, I'll assume that you know this stuff.
The Do (pronounced ‘doe', as in deer) is the torso armor. It's important that you make it right and that it fits properly, or you'll be really unhappy. The Do is made of 11 to 13 plates: five primary torso plates, two or three top front plates, two or three top back plates, and two shoulder straps. (SEE DIAGRAM 1-1) Please note that the Do is based upon the rectangular front and back pieces -- everything else attaches to or hangs from them. The Do is the most difficult piece to make, so it's best to get it out of the way first.
The steps for making the Do are:
A. Measure your body
B. Use your body measurements to make a pattern from poster board
C. Tape the pattern together and see if it fits. Modify the pattern where necessary
D. Tape the pattern pieces to your barrel
E. Cut out and finish the pieces.
F. Drill the pieces and lace them together.
PATTERN ASSEMBLY AND FITTING
Now it's time to tape your poster board pattern together and try it on. I recommend using electrical tape, because it peels off very easily. (SEE DIAGRAM 1-5)
* Begin with the major plates. Leave a gap of about 1/4" between the major plates when you tape them. Once they are all together, underlap the top plates by ½" and tape them in place.
* Fit the pattern around your body, overlapping the plates on the right side. The top front plate should be within a few inches of the hollow of your throat. If the pattern is too high, remove one of the plates.
* The top back plate should be within an inch or so of the base of your neck. If it is too high, remove one of the plates.
* Now comes the shoulder straps. Begin by taping the rounded end next to (but not on) the front top plate.
* Slide the back end under the top back plate and tape it in place. Repeat this with the other side.
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