Sourcing the original materials for making the arm and shoulder gear as worn by Kevin Flynn, Tron, Ram, and Crom proved to be very difficult. There is a great thread on TheRPF.com from 2010 wherein MrSinistar works hard to identify these parts in his costume build. Folks on that thread believe the arm and shoulder gear to be parts of a Jofa-brand motocross chest protector.
While it isn't clear on TheRPF.com if MrSinistar and others completely figure it all out, I do believe they are correct about the parts being Jofa. I'd been searching the Internet off and on for months, and recently on eBay I found a vintage 70s Jofa chest protector with arm pads that look identical to the Disney prop; however, the shoulder cups are not the same shape, being too elongated and vertically too thin.
Exhaustingly, I then found a second vintage 70s Jofa chest protector with what I believe are the correct shoulder cups. This was nearly impossible to find, but I did so through a Google image search that showed this unit as a no-longer-listed eBay.ca item. I contacted the seller directly, and it turned out he still had the unit.
When one combines the shoulder cups from this second chest protector with the arm pads from the first, we can see that this appears to be the real solution for the video warrior arm and shoulder gear:
Completing the materials search for the arm and shoulder gear was a whole lot of fun, requiring a lot of patience, relentless Internet searches, and monitoring of eBay until the right two Jofa chest protectors revealed themselves to exist on the planet Earth. I greatly look forward to finishing and detailing these extra-special pieces. Only solutions!
Lots of work accomplished on the shoulder pads/arm guards. First, here are the reference images I went by:
I used Jacquard Neopaque white fabric paint to cover the orange portion. This took many coats and lots of sanding to turn the rough textured fabric into a smooth flat white surface. For the circuit patterns on the arm guard panels, I used ink jet matte white adhesive vinyl sheets. Next steps are to airbrush the connecting circuit lines and rivet the shoulder cups and arm pads together. There are some elastic straps and top snaps to attach as well.
Elastic arm straps are now sewn into place. Also, I wasn't pleased with the above vinyl decal work, as the white vinyl was too bright and didn't match the surrounding enamel paint. So I peeled them off and started over, color matching the background and reprinting them with the off-white matched background. Before reapplying the vinyl graphics, I masked and airbrushed the peripheral lines. All that remains is to rivet the shoulder cups to the arm pads.
At long last, the Kevin Flynn shoulder pads are complete. I think even more than for the helmet, perhaps because these materials were so hard to come by, I am most proud of these replica props. It was an honor to work with these materials in recreating the video warrior shoulder gear. Here are the final pics of this most fun and rewarding piece of the project: