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Borus (Armor) from Suikoden 3
Whew. Where do I even start with this one? I (of course) created this armor using my foam and plastic sheeting method. The most difficult aspect of this project was, by far, getting all the pieces to fit together smoothly and in such a way that the person wearing this armor could still move their arms and legs. (Granted, whoever wears this probably won't be able to perform complex gymnastic routines or fight elaborate stage battles, but they should at least be able to walk and pose without too much difficulty.)
This costume's biggest headache: locating a place online where I could buy the buckles (I needed 16 of them, all identical to each other), and getting ahold of some leather for the straps. (Thrift shops belts work out great in this regard.) I also had trouble locating decent reference pics as, aside from one official character sketch and in-game screenshots, they are few in number. The finished armor ended up being an amalgamation of the in-game image and the character sketch, as they differed slightly from each other. (I just picked and chose what seemed the easiest to do from both sources.)
Estimated time I spent on this project: Around 50-60 hours. Definitely not one for the commitment-phobic...