Paladin Armor Assembly

Please note: I really want these assembly instructions to be the best they can be. If you have any questions on the assembly, you are probably not the only one. Please send me an email letting me know which part is confusing, and I'll add more detailed photos or whatever is needed to make these instructions even better.

Don't have the Paladin Armor Kit? No problem, you can purchase it here.

Kit contains the following parts:

Cardboard armor parts:

Helmet
Helmet top
Helmet horns (x2)
Shield
Shield straps (x2)
Armor top (x2: front & back**)
Armor bottom (x2: front & back)
Armor shoulder (x2: front & back)
Armor shoulder (x2: front & back)
Armor belt (x2: front & back)

**Front & back are identical

Other parts:

Mini rivets (80 pcs. - 40 sets*)
Standard rivets (8 pcs. - 4 sets)
Velcro tab(x2)
Silver Sharpie (optional purchase)

*Extra sets included - parts left over

How Mr. McGroovy's Box Rivets work:

Two identical pieces make a set.
Rotate rivets so prongs are at a 90° angle.
Snap together and teeth will lock tight.

Step 1

CAREFULLY open the box.

When you receive your armor kit, it is shipped flat and requires assembly. If you use a knife to open the box, use extreme care so that you don't cut the cardboard pieces inside the box.

Step 2

Separate the armor parts from the sprue (that's the extra area around the parts).

Some pieces will come out very easily and others will still be attached in a few places. This is done on purpose so that the parts don't fall out in the machine when they are being cut. You want to be careful so that you don't tear the piece. I like to use an xacto knife to make sure all my pieces are perfect. Rather than rushing to assemble this as fast as possible, if you remember that this is a finely crafted model I think you'll get greater enjoyment out of putting it together.

Once you have all the parts punched out, you may want to poke all the holes out as well. It's not absolutely necessary, but it keeps them from getting in the way later on. If you like popping bubble wrap (and who doesn't?) you'll enjoy this.

Step 3 (optional)

Outline the pre-printed design elements using the silver Sharpie marker (included with kit).

Adding the silver lining isn't required, but I can't emphasize enough how good this makes the armor look. It's a very subtle detail that makes a huge difference. Unfortunately it's difficult to capture with photography. The suit comes with pre-printed designs, but the silver lining is something you will need to do yourself that really adds a great finishing touch.

If you want to add any decoration this is the best time to do it - before you've assemble the armor. Now, this is a real Sharpie brand marker, and it's a special metallic one at that, so who knows what kind of chemicals are out-gassing from this thing. Make sure you use the Sharpie in a well ventilated area.

The silver lining is really simple to do...all you do is outline the pre-printed design elements. If you choose to let your child do this part, it can give them a sense of ownership and be a source of pride, and they may want to do something a bit more creative. If they get finished and it looks like a kid decorated it then it's perfect. On the other hand, if you want to do this part you shouldn't feel guilty. It's very relaxing.

Another thing is that lines have personality, and your lines will capture something of your personality whether you want them to or not. By doing this you are imparting something of yourself into the object, and that can be part of the gift. So once you get the kids to bed, grab your headphones, choose a mellow playlist and enjoy.

Step 4

Shield Assembly

From the pre-printed side of the shield, insert 4 standard rivets (the bigger ones) prongs down into the shield holes.

Flip the shield over. Curl the shield handles to give them shape. Place the handle holes over the inserted rivets.

Complete the shield rivets by snapping inserted pieces together with their mates.

Shield assembly is now complete.

Step 5

Armor Assembly

Roll armor pieces #6 - #10 over a round object to create nicely curved parts.

Place each piece over a round object like a spray paint can. Apply pressure as you roll the can to shape pieces. This is very easy to do. Each piece is oriented so that the cardboad fluting goes in just the right direction.

Paladin Armor First assemble the front of the armor.

Insert two rivets into the center holes where the belt will attach, prongs up.

The front and back are identical. You will do both the same way.

Paladin Armor Place the belt holes over the inserted rivets and complete the rivets by snapping them together with their mates.

Paladin Armor Complete the belt section. Insert more rivets into the side holes, prongs up. These rivets will not line up with the belt holes. Roll the armor until the rivets line up, and press the belt holes onto the inserted rivets. Then complete the rivets by snapping them together with their mates.

This is what helps the armor retain it's curved form. This is the only part that's not very intuitive.

Paladin Armor Complete the belt section for both front and back.

Now you are ready to attach the should sections. Place the front section printed side down, and insert rivets into the shoulder holes, prongs down.

Paladin Armor Flip the section over, and place the first shoulder piece (#8) over the inserted rivets - but don't complete the rivet yet.

Make sure you don't close up the rivet yet!

Paladin Armor Place the next should piece (#9) over the same inserted rivets. Now you can complete the rivets by snapping them together with their mates.

Paladin Armor Repeat for both shoulders.

Paladin Armor Time to attach the shoulders to the back section.

It might look like the holes will not line up. Don't worry, they will.

Paladin Armor Place the first shoulder piece (#8) over the inserted rivets (just like before) but don't complete the rivet yet.

Paladin Armor Place two rivets, prongs down, into the second shoulder piece, and pull the piece over so each rivet lines up with it's mate. Snap the rivets together and the armor begins to take it's final form.

Paladin Armor Repeat for both shoulders and the armor is almost done.

Paladin Armor Remove the backing off one side of one of the Velcro tabs and attach it to the belt section.

Paladin Armor Remove the backing off the other side of the Velcro tab to fasten the belt section down. Repeat for the other side.

The Velcro tabs are a 3M product and use a good adhesive. However, they recommend one hour for the adhesive to fully cure. I recommend it also. If you don't wait this long and start using the armor immediately the Velcro comes off much more quickly.

Step 6

Helmet Assembly

Paladin Helmet Use a straightedge (like a ruler) to bend the helmet along the pre-scored lines.

Paladin Helmet Helmet piece (#1) should look like this when you are done bending it. Do this on both the left and right side.

Paladin Helmet It's easiest to assemble the helmet upside down. Insert rivets in the holes along the "top" of the helmet, except for the last hole on each side. Insert one rivet into the flat top section of the helmet as shown in the photo. This rivet should have the prongs facing out.

These holes are designed to be a little smaller so they hold the rivets in place.

Paladin Helmet Place a tab over each rivet and complete the rivet by snapping on it's mate. Start at the front and work your way around on both sides.

Paladin Helmet This photo shows the helmet from another angle. Continue to snap up the rivets until you get to the very last hole.

Paladin Helmet Insert rivets along the back spine of the helmet.

Paladin Helmet Place the top spine rivet hole over the inserted rivet.

Paladin Helmet Complete all rivets along the spine by snapping them to their mates.

Paladin Helmet Insert two rives into the holes for the horns before inserting the horns.

I like to make the horns a little curved. you can do this similar to the way you curved the armor parts but rolling them over a round object like a paint can.

Paladin Helmet Insert the horn into the side slot.