THIS IS A LONG AND DETAILED TUTORIAL FOR ACCURACY OBSESSED COSTUMERS ONLY. Don’t say I didn’t warn you…
Just a little historical past: The one who first found out how you can recreate a screen-accurate Mad Max shoulder pad was Karol B. His unique tutorial is accessible right here: The best way to Make Max’s Pad.
For comfort and consistency I’m going to make use of the identical terminology to explain varied elements of the shoulder pad that Karol utilized in his unique tutorial. You’ll find a information right here: Soccer Shoulder Pads
Since that tutorial was written, Karol and I’ve labored on and off for about two years to create for me the world’s most obsessively correct Street Warrior outfit. In doing so, we discovered lots of particulars in regards to the costume (gaining access to the HD model of the film helped rather a lot) and it’s now time to replace the shoulder pad tutorial.
The unique tutorial continues to be right and will nonetheless be checked out first, as these directions are actually meant so as to add on to it, not exchange it. Not solely have we discovered some new info and methods, however the world of Mad Max costuming has modified considerably, particularly because it pertains to shoulder pads.
When Karol did his unique tutorial, classic Rawlings soccer pads of the proper sort had been pretty simple to come back by. Not so anymore. They’ve grow to be scarcer, and the costs have gone up (perhaps a straightforward to observe tutorial for using them in Mad Max costumes had one thing to do with it?) As well as, the pads wanted are actually (as of 2010) within the neighborhood of thirty years outdated. This isn’t a great factor for these pads. With age, the froth inside tends to harden and grow to be brittle, making them unsuitable for costume functions. Additionally, many pads, both by way of use or improper storage, have mould or mildew issues within the arch padding (an issue that generally can’t be seen in eBay public sale photos and isn’t observed till you may have the merchandise in hand). Lastly, the vinyl strip overlaying the neck roll portion of the pad tends to separate and tear with age and use. For these causes and others, we now have determined to forgo the classic padding and create our personal, however extra on that later.
USING VINTAGE PADS
We not suggest utilizing classic Rawlings pads usually (extra in regards to the new possibility a bit in a while). In case you do intend to trace down classic pads anyway, pay attention to the issues famous earlier, and you’ll want to test Karol’s guides linked above so that you just select the appropriate mannequin quantity to your wants. Additionally, please pay particular consideration to the shoulder plate on the pad, whatever the pad’s mannequin quantity. Karol and I’ve began seeing quite a few pairs of CP-46 and even ER-46 pads which have an incorrect shoulder plate on them. In truth, many pad pairs are being discovered with two plates that don’t even match one another, as if one has been changed in some unspecified time in the future. (As a aspect word, Karol was as soon as fairly positive that Max’s unique pad had been based mostly off of a Rawlings ER-46 mannequin due to the same set he noticed on eBay years again. However we’ve seen a number of of these not too long ago and so they haven’t regarded proper. So it’s laborious to know if the one set of pads Karol noticed was a regular ER-46 or not. I’m beginning to assume not.)
NOTE – Make certain that once you purchase your shoulderpads they aren’t “youth” or “boys”-sized. These shall be too small on the typical man and gained’t look proper.
(And sure, I’ll take a second to say that you could nonetheless make a terrific Mad Max costume with out a 100% display correct pad and/or plate and most of the people gained’t know the distinction, however then why are you studying this? This tutorial is for individuals obsessive about an absurd stage of display accuracy. So let’s proceed…)
For these of you who nonetheless intend to make use of a classic pair of Rawlings pads as the premise to your pad, there are some ideas we are able to provide above and past what’s within the unique tutorial.
The most important drawback with the pad meeting is that the rivets have a tendency to start out pulling by way of the froth padding or the leather-based after some time. We’ve completed 4 issues to assist forestall this:
Pad strengthening ideas:
1. To maintain the rivet from pulling by way of the jacket’s leather-based, we use washers between the rivets and the leather-based on the within of the jacket. You don’t must do it for each rivet; about half of them shall be a lot. Fender washers are really useful right here since they’re huge diameter washers have a small gap within the center that the rivet can’t slip by way of.
2. To maintain the rivet from pulling by way of the froth padding, we now connect strips of cotton to the froth utilizing glue (a rubber cement like Barge model is nice for this). These strips of fabric go between the froth and the polyester material that covers it, in order that they’re hidden (so as to add these strips to a classic pad you’ll want to chop the polyester open on the again and peel it away to connect the strips after which re-sew it as soon as the glue is dry (do that on the again so the work can’t be seen clearly).
3. One different factor Karol got here up with was burning the polyester overlaying of the pad at every of the rivet factors with the tip of a soldering iron. Because the fabric overlaying the padding is polyester, the excessive warmth melts it, making a small ring of melted plastic across the rivet that gained’t tear as simply. Word: this can solely work with plastic-based artificial fibers like nylon, polypropylene or polyester.
4. But yet one more thought Karol got here up with to keep away from rivet pull-through was utilizing tremendous glue. As soon as your rivets are in place, merely apply tremendous glue throughout the sting of the rivet head, permitting the glue to soak into the polyester overlaying behind it. Surprisingly, a budget tremendous glue we used didn’t depart a white crust – it merely absorbed. It’s laborious for a rivet to drag by way of when it’s super-glued to the outer layer. You’ll be able to do that on the leather-based aspect as properly.
Additional to Karol’s recommendations on portray in his outdated tutorial, I can let you know that I’ve had good luck portray the vinyl neck roll and material of my pads with a model of spray paint known as Meltonian. It’s meant for portray leather-based and vinyl and works very properly. It is available in quite a lot of colours (you need black, clearly) and also you might be able to discover it the place they promote shoe restore and leather-based crafting provides, and you will get it on the web.
In any other case, the Rustoleum Painter’s Contact Matte Clear paint listed on Karol’s outdated tutorial continues to be the one different paint we’ve discovered that dries rapidly, even after testing different Painter’s Contact colours.
MAKING A CUSTOM PAD
That is the tactic that we now consider ends in essentially the most display correct shoulder pad. In case you’ve created a dressing up pad from the outdated tutorial, and even simply learn by way of it, you’ll know that to create Max’s pad from an present Rawlings pad, some slicing and stitching of the arch padding must be completed to create the proper form. This was true with the extra widespread CP-46 pad (although none of them are widespread any extra) and it’s additionally true with the ER-46s we’ve seen not too long ago and others. In truth, we now have but to see a shoulder pad in person who has arch padding that precisely matches what Mel Gibson has on in The Street Warrior. So reasonably than modify an present classic pad that doesn’t come out fairly proper, why not make your personal from scratch? This additionally solves the issue of classic padding that has grow to be brittle or rotten.
Outdated pad on the left. New pad on the appropriate (unfinished).
First, you’ll need a piece of three/8″ polyethylene high-density foam, generally known as L-200. It’s possible you’ll must get this from a specialty foam store and purchase a big sheet (we paid about $25). A lot of the foam you discover within the common material retailer shall be too porous and spongy. You need one thing that can approximate the dense micro-pore foam they use in athletic gear. Word: Some craft or material retailers carry the same “craft foam” however that is too dense, too skinny, and often is available in sizes too small to work with.
Utilizing arch padding from classic Rawlings pads and evaluating it to screenshots of Max, Karol created what we consider is a really correct form that approximates Max’s pad.
Karol drawing the template for the froth padding
Listed here are pictures of a minimize foam pad. I’ve written lots of measurements on it with a black marker, so that you just may be capable to create your personal. (It’s possible you’ll must click on on the pictures to enlarge and see it clearly, however hopefully you’ll be able to learn all of the numbers. The measurements are all in CM).
The froth may be minimize with scissors, however ideally, this foam is greatest minimize with single-edge razor blades and a talented, regular hand. The razor blades boring in a short time, but when swapped out typically, can carve out good, even beveled edges on the padding and reduce the quantity of sanding you’ll should do later. Fortunate for you, the padding shall be coated in material later which might conceal lots of irregularities.
Slicing off the perimeters to create beveled edges
As soon as the padding is minimize, you’ll want so as to add a small strip of froth (approx 2cm x 24cm) to make the neck roll space bigger. Simply minimize a straight strip out of the identical 1cm thick foam, minimize the ends and the edges at an angle in order that they slope down after which glue it in place with Barge. Put some weight on it (however not an excessive amount of weight – the froth has reminiscence) and let it dry in a single day earlier than continuing to the subsequent step.
It’s time to spherical off all the edges of the froth padding. To do that, use a moist piece of medium to coarse sandpaper. You want the sandpaper to be moist so that you just don’t simply tear up the froth. It’s possible you’ll wish to apply on a separate piece of froth till you get the cling of it, however quickly it is best to see the froth begin to spherical off as you sand it (bear in mind to maintain wetting the piece of sandpaper, and to interchange it with a contemporary one if it begins to collapse).
The sanded clean neck roll padding
When you’ve bought your padding all sanded, it is best to add these reinforcing strips of cotton talked about earlier (the pad strengthening ideas for the classic pads above all nonetheless apply right here). Gluing the material on to bolster the pad is simpler on this case since you’ll be able to merely glue it on to the froth earlier than you cowl it with material. These will assist maintain the rivets from pulling by way of from put on.
Strips of cotton glued on to bolster rivet websites
I often put some weights on the Barge-glued items for a couple of hours to verify they maintain flat and so they’re on there good.
To this point so good. Now we have to cowl the padding in material. What you need is 100% polyester. The Rawlings pads had gray material, nevertheless it doesn’t actually matter because it’s all going to be sprayed black anyway.
For the material, you’ll wish to minimize two items which are about an inch bigger throughout than the froth piece. That’s as a result of these two items will ultimately be sewn collectively and also you want some overlap.
To stitch the items, flip them inside out in order that once you’re completed, the perimeters of the material shall be hidden inside the duvet. Depart the material unstitched alongside the neck roll space, leaving loads of room, so it gained’t be too troublesome to get the froth inside. It is best to now have a material pouch that you could slip the pad inside. You’ll now have a material coated shoulder pad that’s open on the neck. The neck roll space will get sealed once you add the vinyl there.
Dressing the padding up in its polyester cowl
Talking of which, you’ll want a strip of vinyl (the originals had been white after which painted black, however you may as properly use black vinyl in case any of the paint rubs off – you’ll be spraying it black later both method). The vinyl is sewn over the open neck roll space of your pad, overlapping the material and sealing the entire thing up.
Relying in your expertise and what sort of stitching machine you may have entry to, you could want a professional to do that half. Stitching by way of foam and vinyl with out bunching up the froth may be tough. I introduced mine to a leather-based and shoe restore store. I had them do the subsequent half too:
Now you’ll must put some stitching on the edges of the froth to imitate the look of the unique Rawlings padding. This must be completed concurrently the neck roll since it should additionally require a particular machine that may sew by way of thick, dense foam.
Listed here are some dotted traces that symbolize the place the stitching must be. That is the beneath aspect of the pad, nevertheless it doesn’t actually matter because the stitching goes by way of each side.
otted traces present put on the heavy-duty stitching and vinyl strip ought to go Time to color. Any outdated black paint ought to work for the material, however you’ll really want a particular paint for the vinyl on the neck roll except you need it to be sticky perpetually and rub off on issues.
As for attaching the plate to the pad, and the pad to the jacket, refer again to Karol’s unique tutorial linked firstly.
SOME FINAL ADVANCED TIPS
Karol mentions in his tutorial the leather-based strap/small belt that attaches beneath the armpit when carrying the pad. Since we all know that for the film they used a Rossi boot strap for this, you could wish to take into account having a customized strap made for further display accuracy. I took an actual Australian Rossi boot strap in to my native leather-based store and had them make me two copies, one for utilizing beneath my shoulderpad, and one for utilizing on the again of my knee pad (the knee pad would be the topic of one other tutorial).
Listed here are some closeup pictures of an precise Rossi boot strap. (I’ll try the precise measurements and publish them quickly, I don’t have the strap in hand proper now).
We haven’t talked a lot in regards to the precise plastic shoulder plate that’s connected to the pad. It’s now very laborious to discover a display correct shoulder plate. And it appears that evidently even after utilizing Karol’s recognizing information (linked close to the highest of this tutorial) individuals nonetheless have hassle discovering the appropriate one. Nicely, that’s why Karol and I made a resin duplicate of this plate. For the time being, we’re bought out of those plates, however we now have talked about doing one other run of them within the close to future.
The ultimate pad connected to my jacket:
Listed here are a few pictures of the entire outfit. They’re a bit outdated now as I’ve since made a couple of tweaks and enhancements, however they’re one of the best I’ve bought in the meanwhile. (Pics taken by Adam Chilson)