As with almost everything else in this build, the boot plates were modelled in Rhino...
…and printed on my FlashForge Creator printer.
Instead of using silicone to create a negative mold of the toe, I vacuum formed a thin sheet of ABS plastic over it, and used the plastic shell as pourable mold.
I filled this with 65D resin, and created a sturdier tool for vacuum forming the piece later.
I wanted to cast the tools for the heel plate and the side panels in resin as well, and to make the negative shell using vacuum forming, but I ran out of plastic sheets. So I had no choice but to mold them in silicone instead.
Once the resin casts were made, some sanding and mild Bondo fill work was done to touch things up, and the tools were ready to be vacuum formed over.
I threw them onto my home-made vacuum table, and pulled the parts in .06gauge black smooth/hair-cell ABS.
After the parts were trimmed and painted using the same colours as the rest of the armor…
…they were ready to be attached to the shoes. For the shoes I chose a pair of ‘George” brand shoes from Walmart, which I painted the the same colour as the plates above...
…and then used industrial velcro to affix all the vacuum formed plates to the shoes. I poured some hot glue between the hook and loop strips, which permanently secured them in place.
Thanks for looking!
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