This was a quicky to complement another costume. I put it together using leftover aluminum flashing used for the iron throne below and some thick black synthetic suede.
Instructions to make your own costume iron shirt:
Make the plates.
1. Cut the flashing into shapes to fit your chest and shoulders and mold it to whatever body part you want to cover. Make as many plates as you want; I ran out of flashing.
2. Drill pairs of holes into the corners.
3. Spray paint the flashing matte black.
4. Dry brush the plates silver.
5. Coat the painted plates with your choice of clear protective coating. I suggest this option from Krylon or the more heavy duty can from Rustoleum.
Make the shirt (while you're waiting for the plates to dry).
1. Lay out a t-shirt on top of the synthetic suede.
2. Trace the front and back of the shirt on the synthetic suede. Add a few inches to the bottom.
3. Cut out the traced shapes.
4. Sew eyelet tape to the sides of the cutouts extending from the armpits to the bottom edge.
5. Sew the shoulders of the shirt together.
6. Lace up the sides. Laced up sides are important to adjust the shirt's size so you can wear it over a jacket if you're going to spend all day outside in January pushing a heavy cart around.
Attach the plates to the shirt.
1. Cut various lengths of 18 gauge wire. 15 cm should be enough but it will vary depending on how wide you drilled the holes in the aluminum plates.
2. Loop both ends of the wire through the top of each plate, stick one end through the shirt and twist both ends together between the shirt and the plate with a small pair of pliers. Then tape the ends to the inside of the plates with Gorrilla Tape to keep them from dangling.
3. Repeat on the next pair of holes until you're don.
