How I warm a flat foam piece until it curves over the shoulder, and when to stop.

Tracing, cutting and bevelling the edges so two pieces meet in a clean line.

A dry brush, a sponge and three coats that make plain foam look like old metal.

A coin battery, a strip of lights and a switch hidden under the cheek plate.

Three measurements, one ratio and a test piece cut from cheap paper first.

A walk around one finished suit, with what went right and what I would redo.

A pegboard, some cord and how I stop wet paint from touching anything.

A tour of the room where I cut, shape and paint, and the shelf I would not do without.

How I carry a full set in two bags without crushing a single plate.

A friend in a finished set, a long walk and a list of everything that needed a fix.