Pauldron Tutorial – Part 1

October 26th, 2009 | Posted by admin | Categories: Tutorials
First off cut templates from plastic or other type of hard material
First off cut templates from plastic or other type of hard material
Materials used, Best quality satin finish vinyl, 7-8 oz leather
Materials used, Best quality satin finish vinyl, 7-8 oz leather
Tiger Lily flat orange vinyl, gloss white, or flat black, high quality auto upholstery foam with backing, elastic. Trick to the puffy parts is the high quality automotive foam.
Tiger Lily flat orange vinyl, gloss white, or flat black, high quality auto upholstery foam with backing, elastic. Trick to the puffy parts is the high quality automotive foam.

All materials needed, except for my toys. Rivets, snaps, contact glue, and good quality upholstery sewing machine.
All materials needed, except for my toys. Rivets, snaps, contact glue, and good quality upholstery sewing machine.
Cutout of upper part, preparing to sew to front half of upper part.
Cutout of upper part, preparing to sew to front half of upper part.
Preparing to make first stitch.
Preparing to make first stitch.

First stitching complete, now overlapping for remaining stitching.
First stitching complete, now overlapping for remaining stitching.
Second stitching row completed.
Second stitching row completed.
Stitching for one side of top complete.
Stitching for one side of top complete.

One side complete stitching. Three rows total for each side. 2 black, and one white. One on back side and two on top side, one black one white.
One side complete stitching. Three rows total for each side. 2 black, and one white. One on back side and two on top side, one black one white.
Both sides of top completed and sewed together.
Both sides of top completed and sewed together.
Underside view, trim excess vinyl.
Underside view, trim excess vinyl.

Trimming excess vinyl.
Trimming excess vinyl.
Mark, and create your lines for the white pauldron. Mark with pencil, orange and black, no lines.
Mark, and create your lines for the white pauldron. Mark with pencil, orange and black, no lines.
Insert foam with backing to the bottom as shown, glue this foam to the top to allow for ease of movement when sewing. Sew from top down following the pencil lines. Use white thread.
Insert foam with backing to the bottom as shown, glue this foam to the top to allow for ease of movement when sewing. Sew from top down following the pencil lines. Use white thread.

Lay Pauldron top on vinyl bottom and cutout, leaving enough extra for movement.
Lay Pauldron top on vinyl bottom and cutout, leaving enough extra for movement.
Glue bottom vinyl to the foam, This is critical so take your time.
Glue bottom vinyl to the foam, This is critical so take your time.
Sew the top to the bottom, along the same hidden seam between the white top part and the black top parts.
Sew the top to the bottom, along the same hidden seam between the white top part and the black top parts.

Should look like this when completed, Stitching should be hidden from view.
Should look like this when completed, Stitching should be hidden from view.
Another pic showing sewing between the two top parts.
Another pic showing sewing between the two top parts.

Continue reading part 2…

Pauldron Tutorial – Part 2

October 26th, 2009 | Posted by admin | Categories: Tutorials
Another closeup pic or correct seam distances...
Another closeup pic or correct seam distances...
Top sewed and glued to the bottom on the front white section only. After the two seams are sewed, the remaining front is sewed down to the bottom.
Top sewed and glued to the bottom on the front white section only. After the two seams are sewed, the remaining front is sewed down to the bottom.
Pic of completed front.
Pic of completed front.

Bottom view of front. Airbubbles are pushed out by hand
Bottom view of front. Airbubbles are pushed out by hand
Trim excess vinyl from front of Pauldron only, and trim out excess vinyl from the inside of the neck portion. Leave some for movement, for sewing the next parts.
Trim excess vinyl from front of Pauldron only, and trim out excess vinyl from the inside of the neck portion. Leave some for movement, for sewing the next parts.
Lay template on top of black neck tops, and mark the lines on the bottom outside edges as shown.
Lay template on top of black neck tops, and mark the lines on the bottom outside edges as shown.

Marks should be as shown.
Marks should be as shown.
Take rule, and draw a line between each mark on the Pauldron top. This will be a sew line. Use a ball point pen for this, as it is easy to remove with alcohol after sewing complete.
Take rule, and draw a line between each mark on the Pauldron top. This will be a sew line. Use a ball point pen for this, as it is easy to remove with alcohol after sewing complete.
Lines should appear as follows.
Lines should appear as follows.

Lines again, opposite side.
Lines again, opposite side.
Sew down each line on both sides of the Pauldron.
Sew down each line on both sides of the Pauldron.
Sewing down the lines.
Sewing down the lines.

On the ends, be careful to sew only the back sides, not all the way around. Leave an opening to pull the foam inserts into the slots with.
On the ends, be careful to sew only the back sides, not all the way around. Leave an opening to pull the foam inserts into the slots with.
Should look like this on the ends completed.
Should look like this on the ends completed.
Take pre-cut foam with backing and just as the other parts were marked, mark and cut the foam into the necessary strips for inserting.
Take pre-cut foam with backing and just as the other parts were marked, mark and cut the foam into the necessary strips for inserting.

Foam cut to necessary strip sizes.
Foam cut to necessary strip sizes.
Use of small long needle nose pliers assist in pulling the foam through each slot. This method allow for the most puff for the neck pieces.
Use of small long needle nose pliers assist in pulling the foam through each slot. This method allow for the most puff for the neck pieces.
Example of pulled through piece.
Example of pulled through piece.

Pulling the pieces through.
Pulling the pieces through.

Pauldron Tutorial – Part 3

October 25th, 2009 | Posted by admin | Categories: Tutorials
All pieces pulled through the correct slots.
All pieces pulled through the correct slots.
Pulled through foam pieces.
Pulled through foam pieces.
Now sew around the remaining sides of the Pauldron neck parts.
Now sew around the remaining sides of the Pauldron neck parts.

Completed look almost.
Completed look almost.
After sewing complete, trim excess vinyl from around edges.
After sewing complete, trim excess vinyl from around edges.
Sewing around edges of Pauldron to complete all seams.
Sewing around edges of Pauldron to complete all seams.

Completed inserts and all seams sealed.
Completed inserts and all seams sealed.
3/4" double fold automotive upholstry binding is used to seal all sides.
3/4" double fold automotive upholstry binding is used to seal all sides.
Beginning of sewing of binding.
Beginning of sewing of binding.

Binding is wrapped around the entire perimeter of the Pauldron.
Binding is wrapped around the entire perimeter of the Pauldron.
Binding around neck area is a separate piece from the outside edge binding. The neck binding overlaps the outside binding.
Binding around neck area is a separate piece from the outside edge binding. The neck binding overlaps the outside binding.
The neck templates are laid out and marked on the leather, notice all holes are pre-marked.
The neck templates are laid out and marked on the leather, notice all holes are pre-marked.

Elastic, 12.5 " pieces are cut, and leather pieces are sewed on.
Elastic, 12.5 " pieces are cut, and leather pieces are sewed on.
Leather pieces are cutout, and holes punched.
Leather pieces are cutout, and holes punched.
Holes punched.
Holes punched.

Leather neck pieces are laid out, and punched, and rivets inserted.
Leather neck pieces are laid out, and punched, and rivets inserted.
Shoulder parts are added, carefully to get the correct placement. Punched, and rivets added.
Shoulder parts are added, carefully to get the correct placement. Punched, and rivets added.
Holes punched ready to take rivet.
Holes punched ready to take rivet.

Neck pieces added, now ready for snap closure.
Neck pieces added, now ready for snap closure.
Snaps used to close neck.
Snaps used to close neck.
Top snaps are added to the front side of the Pauldron, remember Pauldron hangs from the right shoulder.
Top snaps are added to the front side of the Pauldron, remember Pauldron hangs from the right shoulder.

Bottom snaps are added to the back side of the Pauldron, Pay attention to get these correct.
Bottom snaps are added to the back side of the Pauldron, Pay attention to get these correct.
Pauldron is complete, check for correct adjustment.
Pauldron is complete, check for correct adjustment.
Completed Extremely accurate Pauldron 4-5 hrs of work.
Completed Extremely accurate Pauldron 4-5 hrs of work.


Shoulder Strapping

March 20th, 2009 | Posted by admin | Categories: Tutorials



Steel City Convention March 2008

March 16th, 2009 | Posted by admin | Categories: Convention Pics and Info
Steel City Convention March 2008

Steel City Convention March 2008

A great picture from the Steel City Convention in Pittsburg. March 2008

Kenny Baker “R2D2″ and his lovely wife.

They are great people and wonderful to hang out with for 2 days.

Ohio Toy Convention

March 10th, 2009 | Posted by admin | Categories: Convention Pics and Info

chewie_eyes

Convention pic to be proud of.

Pic with Peter Mayhew at an Ohio Con, up near Cleveland. Had alot of fun, not in costume, and met lots of people and made new friends. This is one tall very friendly TEXAN… Shoot he even still has Chewies smile.