Starting with the leather scale jacket of the Zora Armor I decided to make my own patterns for it.
I already had grey leather at home for another project so I decided to take it for the zora armor instead. The scale pattern was complicated enough, but it paid off to make it look nice.
Bought leather suitable thread to make sure the jacket doesn’t fall apart while on a convention or outside on a photo shoot.

To make the jacket and armor more durable I got myself a thick lining.
Here’s the progress of the jacket, belt and greaves:

A lot of metal bits decorate the Zora armor and I decided to give metal casting a go and make them with pewter.
Smooth-On has a nice silicone called Mold Max 60 which is a high temp silicone that can withstand molten pewter.
So, that was the silicone of my choice.
First I sculpted a couple of bits with AVES Apoxie Sculpt and then made a mold with Mold Max 60.
Then of course melted pewter and poured it into the molds. After the cool down the bits had to get through a process of sanding, polishing, and weathering. The blue gems are made of resin which are also made by hand:

All armor parts like the pauldrons, bracers, greaves, and visor will are entirely out of foam. To glue all together I worked with Barge and Renia Colle de Cologne; two contact glues that have the same quality:

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