How to Make Cardboard Armour

Co-authored by Renee Day

Last Updated: November 1, 2024

Are you trying to make some armour for cosplay with your friends? This article will show you how to make a suit of knight's armour using cardboard boxes. Read on to discover how to make a chest piece, shield, helmet, and more!

1

Make the chestplate.

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It should be big enough to place around your torso, over your chest and stomach.

2

Attach string to your chestplate.

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You can use staples or quick-drying glue so that they can be worn over your shoulders, holding the box in the right place (over your chest and stomach). Make sure to measure them and cut them to the right length. Alternatively, you can use string for this step, as it will not be visible in the finished product. You now have a breast plate.

3

Collect two small boxes to use for shoulder pieces.

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Cut them out so there are two sides open on each one - so they can slip easily on to the shoulders, and not restrict arm movement too much. Also, they must be on firm enough to prevent them falling off at every opportunity. These boxes will form the spaulders—or shoulder plates.

4

Build the greaves.

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The boxes you use for these will presumably need to be long and thin. They should be flexible at your leg joint—so you should create some sort of hinge there, possibly by cutting three sides and leaving the last.

5

Make a helmet.

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Cut out an oval shape for you to place your head through, and also the bottom end of the box, for you to put your neck through.

6

Cut out your shield.

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You need to cut some thick cardboard into the shape of your shield. This can be square, kite-shaped, rectangular or any other shape you can think of.

7

Make the sword.

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This will be rather floppy for use on its own, so you may want to attach a wooden stick to it.

8

Paint your armour.

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Try painting some jewels, or a coat of arms, on your armour.

9

Enjoy your armour.

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Expert Q&A

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Question

What else can I use to cut a thick cardboard?

Renee Day
Crafting Expert
Renee Day is a Crafting Expert and Content Creator based in Michigan. She is a master of paper crafts, and also specializes in brush lettering, journaling, embossing, stamping, stenciling, doodling, and crocheting. Her Instagram account, thediyday, has over 300K followers. She published a book called Creative Journaling: A Guide to Over 100 Techniques and Ideas for Amazing Dot Grid, Junk, Mixed-Media, and Travel Pages. The book contains 52 projects, from crafting colorful pages to creating dot grid, junk, mixed-media, and travel journals. She also created Chunky Letter Calligraphy, a 30+ page (PDF) all about lettering. She runs a thriving Amazon Storefront, where she curates craft supply collections for her followers. She previously worked as a photographer, capturing engagement sessions, weddings, boudoir, and landscapes. She received a Master’s Degree in Marriage and Family Therapy.

Renee Day

Crafting Expert

Expert Answer

For thick cardboard, I’d go with a craft knife and a metal ruler. Using a craft knife will cut through the cardboard way easier than scissors, especially if you make a few light passes to avoid tearing. Also, a metal ruler is key here because it’ll guide your cuts smoothly without getting damaged, unlike a plastic ruler that might get nicked by the blade. Just line up the ruler where you want to cut, and gently run the craft knife along the edge and repeat until you’re done with the cardboard.

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Tips

Add personal touches to your armour, such as creating your own coat of arms.

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This will probably not win any costume contests, but it will be fun to make and play in.

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Warnings

This armour is only for a costume or playing, and will not protect you from real sticks, arrows, swords, spears, javelins, nor from the Undead.

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Helpful 55 Not Helpful 13
This type of armour does not work well in rain.

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This will not be very flexible, and not so easy to move around in.

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