It turns out that vacuum forming is actually kind of difficult - who knew?!
So this first pull looks pretty good, but that's thanks in large part to the thickness of the plastic. This wolf head shoulder pad is flimsy - we're talking bottom-of-the-rack toy masks from Wal-Mart cheap.
So, we upgraded. T-paint is the the one who's really going to be doing a lot of this stuff, so she got a *ton* of .060" black ABS plastic sheeting.
Then we fired up the oven.
Whoops. Yes, that is a burn mark on the vacuum panel, there. Turns out heat guns can really do a number on, well, pretty much anything. We're following the standard idiot's guides to low tech vacuum forming found online, which means there has been some trial and error. Still results are improving:
Thus far, the Corps has only incurred one proper burn during vacuum forming, which means it's still less dangerous than hot glue guns. It's a rare and happy day when an upgrade in costuming technology doesn't come with commensurate increase in danger, so... be happy for us.
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