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The cuirass worn by Theoden is the single most difficult piece to
build. The basic style is based on the old Roman lorica segmentata. One difference
is that Theoden's cuirass overlaps in a backward pattern from that of the
normal lorica.
The first step was to make a full size mock-up of the breastplate in posterboard.
We were able to mark on the posterboard all the alterations need to get a proper
fit in the final pieces, and how they needed to align.
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The individual pieces were cut from plastic using the posterboard
as a template. They were curved into the proper shape by gradually cold bending with
hands.
A matching piece of leather was cut for the back slightly larger than the
plastic piece it would cover, and a sandwich was made. Maroon vinyl lining, the
ABS plastic and finally, the leather. The red leather horsehead insignia was
glued in place and the brass buckles riveted on. There are 3 buckles on each
side, one on the shoulder for the cuirass strap and another on the shoulder
for the pauldron strap.
Costume photos of one cuirass back show additional straps and buckles to act
as belt loops for the sword belt, but this was not consistantly done with every
one of the various replicas that we have seen. We have decided wait to add these
additional straps until we determine whether they are actually needed.
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After the plastic for the front was cut, the design for the leather overlay
was traced onto the posterboard pattern showing the alignments and overlaps for each
piece. The locations where brass would show through was marked, and shim brass
was attached in those locations. Places where the brass was embossed were filled
with embossing brass, hand embossed in appropriate designs.
Leather pieces were cut to match the entire design on each piece of cuirass,
including the overlapping areas, so that no blank places would show as the panels
flex. These are also hand embossed wherever the patterns are known.
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In this photo you can see most of the pieces of the front prior
to assembly. The plastic will wind up sandwiched as before, between the
vinyl lining and the leather outerlayer. In the case of this piece however,
you will be able to see sections covered by brass through the leather, and
an additional step will attach a vinyl piping trim all around the edges.
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