Started with a mock up that I doodled all over. This was cut up and used as a pattern.

Base fabric is a thick blue spandex that actually has a texture, but I used the wrong side of it. The fabric is smooth on that side but a little of the texture shows through so it is more visually interesting. Darker blue details were done with a weird textured knit I got from a friend. Red details were made from a sort of athletic mesh that I had to double up on because it was so thin. Silver details were done with spandex. Raised details were done by layering craft foam between fabric layers.

Basically when sewing this together I had to use freezer paper ironed onto my shapes so that when I cut out the spandex it didn't move around and came out exactly that shape. That's the trick to this.

Belts were made out of a light brown vinyl that I stained with t-shirt transfer ink (no joke). Gloves are leather work gloves from Home Depot that I altered and were stained the same way. Both were further weathered with sandpaper and acrylics. Belt buckle is a real snap buckle cleverly hidden with craft foam. Strap slides were bought from an upholstery store, painted and weathered to match. The large buckle on the back straps (not shown in any of these pictures, sadly) was made from coroplast and craft foam (this was before I had money for good materials, okay??)

Boot covers are made from metallic spandex with a thin layer of batting. Buckles and belts were painted and weathered to match everything else.

Shield is a cheap plastic Halloween prop that I painted in the hotel room. NO MAGIC THERE.

More WIP photos + explanations here: http://luluko.tumblr.com/tagged/captain-america