Construction Details:

I was working on Al for Anime Weekend Atlanta 2006. My friends were also going to cosplay from Fullmetal Alchemist, so I was determined to get it done on time. I made a template out of thick posterboard and taped it all together. Next, I cut the tape and used those sheets to trace out the pattern on large sheets of plastic. Then I cut the plastic. The plan was to then assemble that all and paint it. ...but time caught up with me. I wasn't going to get it finished in time!

There was only one thing I could do...paint the posterboard template and hope for the best. I spraypainted it the day before heading down to the con, but ran out of paint for half of the last arm piece. I had to use a slightly darker gray there. After it all dried enough, I stuffed it in a couple clear plastic tubs, taped them shut, and checked them with Delta.

Arriving in Atlanta, Delta had lost one of the tubs! They delivered it to the hotel the next day. The pieces in the other tub suffered some damage when apparently TSA had opened them for inspection (even though the tubs were clear and you could see everything inside clearly!) That damage was repaired fairly quickly, luckily. We reinforced parts with clear packing tape to make sure it would all hold together.

Walking around the con in this was an amazing experience. Yes, Al was skinny, but people still loved the costume! Walk 5 feet, stop for pictures. Walk 5 feet, stop for pictures. Repeat. Amazing!

However, the posterboard DOES NOT breathe. After four hours, my sweat was taking its toll. The sides and back of the chest were ripping...and the insides of the upper arm pieces too. Going back to the room, I had to be torn out of the costume. It can never be worn again.

Fortunately, I CAN use most of the pieces as a template for when I make Al again...and out of plastic this time!

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