Homemade Samurai Armor

Written by erica porter
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Homemade Samurai Armor
(Bec Parsons/Photodisc/Getty Images)

Every youngster wants a memorable costume, whether for Halloween or a costume party. Being a Samurai Warrior is about as memorable as you can get. This is a great project for a rainy day, a birthday party, or in preparation for Halloween. The items needed are easy to find and require no sewing or previous crafting experience. So gather the family and friends who want to be really creative and have fun and enjoy making this project.

Skill level:
Moderately Challenging

Things you need

  • Paper
  • Marker
  • Baseball helmet
  • Scissors
  • Foam core poster board
  • Outdoor garbage cans
  • Craft knife
  • Tin snips
  • Power drill
  • Newspaper or garbage bags
  • Spray paint
  • String
  • Bolts and washers

Show MoreHide


  1. 1

    Draw out the patterns for each of the armour pieces with paper and marker. You should make a front and back chest protector, shoulder straps, upper arm coverings, forearm cuffs and a helmet "skirt" to make your helmet flair out.

  2. 2

    Cut out the paper patterns with scissors and lay them out on the coordinating material. Use the foam core board for the shoulder coverings and the garbage cans for all of the other pieces.

  3. 3

    Trace the patterns and cut them out, marking the back of each one so you can identify which piece of armour you are using the pattern for. Use tin snips to cut the garbage cans.

  4. 4

    Score horizontal lines on the shoulder coverings with a craft knife to allow them to curve with the contours of your body. You shouldn't cut all the way through or you will cut the coverings into many pieces.

  5. 5

    Make a mark at each point where you will thread strings through the armour pieces (except the helmet skirt). You will need to have strings in the arm cuffs, at the ends of the shoulder straps, and at the tops of the chest and back protectors to tie these pieces together.

  6. 6

    Use a power drill to make a hole at each of the marks you made. You can use the drill on both materials. For the helmet skirt, you just need to drill holes where it lines up with the holes that are already in the baseball helmet.

  7. 7

    Set out the armour facing up on newspaper or on a garbage bag to protect the floor you are working on. Spray the pieces with spray paint or a mixture of paints to get whatever finish you want.

  8. 8

    Let the paint dry thoroughly before feeding the strings through the holes. Tie knots on the ends of the strings to keep them from falling out.

  9. 9

    Tie the armour together, leaving enough space untied for you to slip the pieces on. Set the armour aside.

  10. 10

    Spray-paint the helmet the same colour you used for the armour.

  11. 11

    Wrap the helmet skirt around the helmet so the holes line up. Push a bolt into each hole and secure it with washers. You can also use glue between the skirt and helmet to provide extra strength.

  12. 12

    Lace the forearm cuffs with string as you would shoes and slip them onto your arms. Once they are in place, you can tighten and tie them, just like shoes.

Tips and warnings

  • Have a friend hold the pieces against your body to determine exactly where you want to place the string holes.
  • You can add studs, ropes and other details to make the armour look even more authentic.
  • This armour is purely for entertainment and will not provide any protection whatsoever.

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