Sorry, this is going to be a long post with lots of explanation. I know no one likes to read posts this long, but I would greatly appreciate it if you could read through it and help me brainstorm what I can do to solve my problem! It's hard to briefly explain this part of my armor over the Internet, so I'm going to do my best to make it clear what exactly I need to be able to do.
So, I'm stuck on a part of my leg armor. Specifically, the black armor that goes on the back of the calves. Reference: http://img.photobucket.com/albums/v3...preference.jpg
See the notes in the blue circle for the exact part.
Since I am trying to make my 5'4" body the size of a bulky 6 ft guy, I am compensating for height by using 8 inch heels, and building a shape around them to make the shoes of the costume look like they are low heel. In actuality, my real heels are 8 inches off the ground, which puts my heels inside the lower calf of the costume's leg.
Pictures of my shoes:
(my hand is holding where the velcro is at the heel)
the back: http://img.photobucket.com/albums/v3.../lowerleg2.jpg
Here's where it gets difficult to explain, so bear with me. x_x;
Right now, to make the transition from the calf down to the SHOE's heel (the fake heel), I have a piece of EVA foam covered with felt attaching at the upper calf and at the shoe heel with velcro. The bottom of the foam piece (the heel) has an extra extension of felt that extends out past the foam, and the velcro is attached to the felt extension. I did this because the piece needs to be able to hinge just above where the velcro attaches at the heel, and the EVA foam itself will not flex enough without pulling the velcro off the heel. The extra flap of felt (with the velcro) flexes just fine on its own, because it's felt. The EVA foam is meant to just fill out the shape of the calf and cover my real heel, and is meant to be hidden underneath the outer armor. Without it, it looks like an unnaturally skinny leg connecting too far up on the foot. In other words, MY calf is sort of where the shin bones should be on this leg I am trying to build, if that makes sense. (I told you, this is difficult to articulate, lol.)
Now, because this EVA foam piece attaches to the shoe's heel/fake heel, this means that it extends past my real heel. I would love to just wear the EVA foam piece under my bodysuit, but it pokes out past my real heel, so that wouldn't cover it enough.
ONTO MY DILEMMA! I am trying to make the outer armor for the back of the leg (the black part). I tried using craft foam and heat forming it to the shape of the back of the calf. The problem is, I need it to wrap around the back and sides of my leg, not just the back part. Why? As you'll see in the first reference, the black armor goes all the way around to the front, and is seamlessly covered by the white armor on the shin. The top calf area isn't a problem, because it doesn't wrap around the leg much there. It's the lower calf area that is difficult to shape.
I tried melting the craft foam down as much as I could with my heat gun to get it to form into the shape, but had no luck. It seems to be impossible to get it to curve at the heel AND get it to curve in two other directions to go around the fake ankle/lower leg. I tried wrapping some slightly stretchy pleather around the EVA foam piece to see if that could stretch enough to wrap around the front, but that only resulted in the fabric creasing and rippling.
I've thought of using Wonderflex. I think I could achieve the complex shape with that, but the problem is that it isn't flexible, and this piece NEEDS to be able to flex at the bottom. (I need to be able to walk!)
I'm really out of ideas for this part and am not sure what I can do. I'm hoping someone can help me brainstorm this.
If any part of this is confusing and needs clarification, please let me know and I'll try my best to make it make sense! Thank you to anyone who takes the time to read this and help me out!!