Cardboard box mock-up
From scaled drawing I made the first mock-up out of an of cardboard.

Ply rib construction of main body
I used a jigsaw to cut the 12mm ply wood frame which was glued and screwed together.

Rear of the Year!
Rear view of ply framed body.

Body side view.
Side view of body revealing leg hole detail.

Cladding body
The body I clad with cardboard, fixed down with a heavy duty staple gun

Good old paper mache'
The cardboard clad body was covered with multiple layers of paper mache'.

Smoothing body with plastic padding.
Not content with the finish of the paper mache' I decided to cover the body with car body filler, sanding between each coat.

Body construction finished.
I built up layers of filler masking different sections to create the strapping, then I drilled out snipped to lenght and glue over 100 upholstery nails to out side of the body before applying several coats of white undercoat.

Finished Body (front view)
Finished front view of body with 3mm plastic brass coloured (spray painted) plate, covering the control panel.

Finished Body (close up)
Close up of the aged paint work.

Side view Tecno trousers ex nasa
Complete with labelling Techno Trousers Ex Nasa also aditional label on other side "does my bum look big in this"

Shoulder Straps
Detail showing padded shoulder straps