Trooper armor for skinny arms

[squirk]

I am printing some Sith trooper armor for my 12-y.o. I scaled down the adult-sized STLs to about 80%, and that seems to be working just fine in terms of length.

 

However, he's a bit of a string-bean at the moment, and his arms are a little thin for the scaled-down armor in terms of width - notably the forearms and biceps.  I haven't printed the shins/thighs yet, but I am assuming I will have the same issue.

I am guessing the obvious solution is to buy foam of some sort, and stuff it into the pieces so that they "hug" his arms and don't slide around/off.  But I don't have a lot of time for experimentation on what foam to use, the best way to cut/install it, etc.  I am guessing that there is a better process than "just stuff some batting in there."

My hope is that there is a tutorial out there somewhere (or at least, a part of a larger armor tutorial) specifically taking about armor and skinny arms, but my Google searches must suck because I'm not finding anything on-point.

 

I'd be grateful if someone would be kind enough to point me in the right direction.  

Please and thank you.

[tk-roamer[501st]]

You could look into sportswear sleeves with built in padding like this https://a.co/d/gjyg0k5

I'd suggest slightly oversized sleeves if you go that route so he can pull the "elbow" pads up to his biceps.

Or cut strips from a puzzle-type floor mat like those sold at Harbor Freight 

https://www.harborfreight.com/4-piece-anti-fatigue-foam-mat-set-94635.html

 

Best of luck with the build.