Yep, with Halloween quickly approaching, this topic is on my mind heavily too. Even more so, because our local Halloween festival is the weekend BEFORE actual Halloween.
Two years ago, I built a Robocop costume from scratch (you can browse through images of it in the directory at
http://www.davidraasch.com/images/robo ), using reference photos only. I built it out of significantly light-weight materials: posterboard, craft foam, and those plastic "for sale" signs you can buy at WalMart. (I didn't know about this board's existence at the time. Used ideas from cosplay.com and robocoparchive).
Back then, I used sets of suspenders (cut up), old belts, and the kind of Velcro that has is "industrial strength" and has a sticky-backing (which I bought from a local craft store). This worked fine for keeping the shoulders and upper-arms on.
However, when it came to keeping the thighs "up", belts and sticky, strong velcro just could not "cut it". After an hour or so, the gluing on the back of the velcro started stripping off of the leather belt. A friend of mine and I determined that it was the back-and-forth action of the thighs, rotating at my hip bones, which was causing too much stress on the Velcro connection. Only one leg was experiencing the problem at first, so he busted out a rivet gun and riveted the belt-and-velcro back into place. This worked nicely for the rest of the night. (However, an hour or so later, the other leg failed... and I was at a costume contest without my friend or his rivet gun. I STILL took first place, even while trying to hide the fact that one of my thighs was slipping off every few seconds.)
So, I probably need to research riveting a bit and figure out how to do it properly on my own.
Now, regarding connecting the chest and back: I had tried using very wide (4 inch?) strips of velcro on each shoulder. Did some test runs with my duct-tape-dummy wearing the armor. The two pieces of velcro on each shoulder would start separating from each other after a while on their furthest ends. So.... I went back to the craft store and bought... snaps. Added those into the Velcro and the layers of posterboard / foam / plastic that were underneath.
This did manage to stay to attached for me for several hours at a time, but the velcro seemed to still "want" to separate. I had the feeling that the sheer weight, plus the curvature, of both the chest and back were contributing to that problem.
I'm telling you all that background because I thought perhaps that info might help somebody. But I do have a concern:
So, here we are this year. I'm building War Machine. And now I'm using the "rondo" method / fiberglass resin + bondo. Heavier stuff. This has me very concerned about how I'm going to connect the chest and the back this time.
I read earlier in this thread about the person who drilled holes and used bolts to connect the chest and back. I'm wondering: Are you putting the nuts UNDERNEATH the armor? I mean, I'm wondering how you put this on / take this off ? It sounds like you're trying to make the bolts blend in, which sounds great. But I'm thinking that you must have some padding between those nuts and your shoulders. Plus, you must need a lot of help taking this on and off ?
I was thinking on going with a hinge system, but honestly, the bolt method sounds less likely to fail. I'm assuming you use some rather large washers, to help distribute the tension?
Thanks!
-= Dave =-