Making Armor

• 1). Make the basic red tunic of the Roman legionnaire by using an extra-large red T-shirt that’s long enough to fall to mid-thigh.
  
  
• 2). Measure, mark and cut two rectangles of corrugated cardboard, each 24 inches by 20 inches to make the front and back of the chest armor (adjust the size according to the size of the wearer).
  
  
• 3). Mark the center point of one 20-inch side of the cardboard you’ve cut, then measure and mark 4 inches to each side of it. Take a measurement 4 inches down from these marks to make a square that’s 8 inches on each side. Cut out the square for the armor neckpiece. Repeat on the other piece of the cardboard.
  
  
• 4). Cut two pieces of corrugated cardboard 6 inches by 10 inches. Place the larger pieces of cardboard with the cut neck holes facing each other, and move the pieces 6 inches apart. Lay the card you’ve just cut so the ends are equally over each shoulder of the larger pieces. Secure them in place with two brad fasteners (available from office supply stores) on each end. Cut two lengths of cardboard, 12 inches by 1 inch, to be waist straps. Try on the armor. Use the waist straps to hold the armor in place over the stomach, securing it in place with a brad fastener on the bottom corners of the front piece and then pulling as tightly as needed before inserting another brad fastener on the back piece.
  
  

Making a Helmet

• 1). Make a circle 15 inches in diameter on corrugated cardboard and cut it out. Draw a line across the middle of the circle and cut. Fold back 1 inch along the straight edges and secure together with brad fasteners to make the basic helmet.
  
  
• 2). For the cheek guards, cut two sections of cardboard. Make them long enough to reach the jawline (approximately 8 inches), and 2 inches wide. Glue them to the helmet.
  
  
• 3). Paint the helmet and armor silver with a paintbrush.
  
  

Completing the Costume

• 1). Cut a sword from cardboard with a straight blade 20 inches long by 2 inches wide and a triangular point (the Roman short "stabbing sword" used the the infantry). Make the guard 4 inches wide by 1 inch, and the handle 4 inches long and 1 inch wide. Paint silver and leave to dry.
  
  
• 2). Put on the red tunic, the armor and the helmet. Fasten one leather belt around your waist. Put the other over your left shoulder, then loop it around so it’s under the waist belt on your right side and fasten it. Slide the sword through your belt.
  
  
• 3). Complete the Roman legionnaire costume with a pair of sandals.