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After all the armour pieces were printed on paper, I used rubber cement to attach them to my 24" x 18" pieces of High Impact Polystyrene plastic, and used a scroll saw (thanks Uncle Dave!) to cut all 384 pieces out. Many of the pieces looked very similar to each other, so in order to distinguish which ones went wear on the suit, I labeled plastic bags as different sections of the body, and kept each group of armour pieces isolated from each other.
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