For the inner bicep pieces we created a slip double layer slipcover.We drilled holes and filed them down to create slots for the straps to weave in and weave out. We then filled the other area with thin foam. The cover then slipped on smooth over top. We are going to glue and paint them, then screw the outer bicep plate (i.e. the stripe) on to the elastic strap. The entire bicep piece will become a slip on.
The picture below shows the abdomen plates in progress complete with beveled edges. We will be sewing leather to my shirt and then gluing the pieces on to the shirt. Will we will be paining and tinting all the aluminum on the costume.