Andrew sculpted the character in clay over a regular mannequin. The body was then section up to cast plaster moulds to reproduce the surface texture. These were set in a framework with an internal mould face, thus creating a cavity.
The framework had clamping devices that allowed Polyurethane cushion foam to be injected into the cavity. The plaster faces of the mould were washed with latex rubber, which coagulated on the surface forming a flexible skin.
The result was a body piece that had a durable rubber surface, backed up by a flexible cushion foam.
When all joined together, the finished warriors costume not only was durable enough for fighting, but it offered a significant amount of protection for the actors.