Celefinniel's Comrades in Arms Pages

Using the scale pattern which can be found on the ACS website a brass master was embossed, and set into a clay matrix for stability.

The second photo shows the rest of the supplies needed to make the scales. We decided not to cast them from plastic since that was known to create brittle scales. Instead we used the ABS scales as a base and bonded the embossed scale to it.

To create a scale, carefully press heavy duty aluminum foil into the brass mold. Put the shiny side toward yourself and the matte side toward the brass master. Be sure to ease the foil into all the crevasses. A wooden embossing stick or blunt pencil works well for this. You can even use the eraser end of the pencil. Above all else don't tear the foil.

Fill the embossed foil with a layer of Flexall and peel it from the mold to dry.

After the Flexall firms up, trim the scale and shape it to fit onto one of the ABS scales that you will use as a base. Fold a small border of foil around all the edges over the Flexall and then glue the Flexall to the scale. We used Weldit epoxy and have had no failures. Spray the scales with Krylon metallic gold. For touch-ups on the scale I keep a gold leafing pen (similar to a magic marker) in the repair kit. The paint will tend to scratch off the scales as they rub on each other over time. This does not really look bad, but I keep the pen for any major repairs. It is possible that if you use a metal primer coat first, the paint might stay on even better. We did not want to risk too many coats of paint blurring the design.

The scales were inserted in among the other scales during the sewing of the skirt to make the pattern. The skirt actually has three different colors of scale in it, which you may be able to see by looking closely at the photos. The one on the previous page shows the colors and the layout of the design better. The plain hammered "steel" (which are painted with hammered silver), the embossed scales, and a few unembossed scales which are painted hammered gold.

The pattern of the scales was worked out on the paper mock-up from photos of the original. For those who are really observant and want to know, yes the skirt DOES overlap in back and not in front, as does the original. We were told that it was constructed prior to having the actor's measurements, so we made ours to match.

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