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1. Use some form of strong glue for example hot glue, though it might come apart after a few years. (NEVER elmer's glue) Also use vinyl spacking, textured spraypaint, printing paper- (the one with gloss on it) and regular 1cm thick cardboard, strong sharp scissors, you can make nearly anything that needs armor.
If you want pauldrons (shoulder armor ) simply cut out a few long strips, glue them into a half bowl shape, glue the inside with many pieces of scrap cardboard, cover the outside strips with vinyl spacking, sanding and spraypainting, you have a durable piece of armor. Or if you want to make a articulated (movable, bendable)piece of armor, cut out a few pieces, use some brass tacks (the kind that has legs and pinches up) glue some smooth paper onto the cardboard pieces, spraypaint, add some cloth straps and you have a fully articulated piece of armor.
It really just takes common sense, and a gift of art. PS: once I am able to post pictures on the forums, I will show you what the heck I am talking about.