CelticRuins 2014 Halloween Costume Contest Entry: Gimli - The Lord of the Rings

CelticRuins

Sr Member
Another Tolkien costume by CelticRuins?? NOOOO.

:p. I've wanted to make Gimli since FotR came out. He's one of my favorites in the books as well as the movies, and much to my Legolas' chagrin...it's happenin'.

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I've started out making the chainmaille and the helmet.

I'm making a dicky for the maille, mainly because it doesn't need to be a full shirt, as only the sleeves and a bit of the skirt can be seen. I'll just be making sleeves and a vinyl/leather trimmed tunic that the rings will attach to. His rings are actually hexagons...but where the hell am I going to find hexagons? So I just opted to get plain, nylon washers. Yes I'm going to be a wuss and use plastic rings. I'm making a FAT SUIT for this and wearing it at Dragon*con....all metal maille is not an option for this chick with a bad back lol.

The middle rings are in fact metal chain rings, but this baby is baby will be light as a feather. I think they'll do fine.
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For the helmet, I toyed around with using a batting helmet as a base. When I couldn't find a decent batting helmet at a good enough price, I decided to just say the hell with it and cut my own base.

I have a bunch of EVA foam laying around, as excess from our Skyrim costumes, so I started with that. Drafting out a base pattern with reference shots. (picture of the wool fabric and the dye for the tunic as well)
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A trashcan makes a great helmet holder btw...

After much filling, sanding, filling and sanding, etc. I put a 1 layer coat of resin over it and then spray painted it to see what else needed to be filled and if there were any pot holes. There's still some leveling to do, but it's getting there.

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Wanted to get started on the knot work while that was all drying, so I drafted up the cheek guard pattern and the emblem in the middle of the helmet (not pictured).

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Got the foam base all set up with a vinyl stand-in for the soon-to-come leather flap in the back.
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Build thread continues below! PROOF PIC COMING SOON!


The most challenging part of this entire costume was probably the helmet build, and then eventually wearing the entire piece. It was the warmest costume I've ever worn due to the fat suit and all the prosthetics. I could only wear him about 2-3 hours at a time, unless I was sitting down! But I learned so much through this process and Gimli was so fun to make and to wear regardless of the heat! And tricking people into thinking I was a man when I walked into the woman's bathroom at Dragoncon...LEVEL UP!

This costume allowed me to delve, briefly, into chainmaile working and making beards and mustaches. I had ventilated wigs in the past, but this was my first time completely constructing a piece from the ground out! The beard consists of tracks sewn on to lace tulle, and as you get towards the face, I've ventilated all the hair in to look more natural and to cover up the tracks. The mustache is all hand knotted onto a piece of lace tulle. All of my prosthetics are made from your basic gelatin prosthetic recipe. The sugar free syrup is used solely for the sorbitol it contains. But it's not a requirement, it just allows your gelatin to hold up a bit longer. These are one time use, usually. Mainly because they melt, but the edges can be blended away seamlessly with witch hazel.
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Re: Fellowship Gimli - The Lord of the Rings

Look's great! Gimli's costume seems to be something a lot of fans don't attempt to replicate. Good luck and have fun!
 
Re: Fellowship Gimli - The Lord of the Rings

Thanks guys!

Not much to report other than I've begun casting the knot work for the cheek guards, and getting ready to cast all the other knot work bits that go around the brim of the helmet. That and I've done more chaining. No photo evidence of that though :p!

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Re: Fellowship Gimli - The Lord of the Rings

Looking good so far! I've always wanted to tackle a gimli helmet myself so I'm curious how yours will come out
 
Re: Fellowship Gimli - The Lord of the Rings

Nice! can't wait to see the result :) i have a Aragon "strider" costume and i have a full metal shirt... yes it's heavy as hell so i can understand your choise of plastic rings and not go a full shirt :D good luck with this awesome project
 
Re: Fellowship Gimli - The Lord of the Rings

Thanks guys!

Finishing putting on all the detailing, then I'm covering it in resin. Hopefully will have it all painted by tomorrow. Then I'm going to start the leather detailing on the back.

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Re: Fellowship Gimli - The Lord of the Rings

Waiting for a second coat of resin to dry, then painting tonight. Currently working on the vinyl/leather backing.

YAR!

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I also just bought the cheapest auburn wig ever lol...but I have to wreck it anyway, to frizz it out, so spending $40+ on a nice wig would be a waste. I'll be adding a lace front to it too. Waiting until it gets here before I order a second on to use for the hair for the beard and brows.
 
Re: Fellowship Gimli - The Lord of the Rings

Quick peek before I finish the detailing and add the leather flap with shingling! Then I'll retrieve my good camera, and stop using my tablet's crappy one...

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Re: Fellowship Gimli - The Lord of the Rings

Helmet is done! Now for the maille, wool over coat, braided leather, belt buckle, 3 axes, prosthetics, wig, beard, boots and a partridge in $##@$%$#^$ pear tree! I'm insane.

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Is it perfect? No. Do I care? Hell no. This is pretty much the best I could have done from scratch!

Patterned out and cut from EVA foam. Details are foam and resin. Back flap is several different types of leather. Chin strap is hand tooled, sewn and dyed.
 
Re: Fellowship Gimli - The Lord of the Rings

Starting on the main battle axe. I've got one of his bearded axes patterned out as well, but I'm focusing on the main axe at the moment. Not pictured is the plank of wood I'm planning down on the sides for the handle.

Excuse the crappy IPad pics...

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Question: Has anyone successfully gotten the hatch mark pattern out of the back of the foam? Sanding? Latex layering? I was going to double up the foam, but that would make the blade very thick and unnatural looking. Far more cartoony than I want.
 
Re: Fellowship Gimli - The Lord of the Rings

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This week on Wood Working 101….
Using a hand sander to bevel the edges of the axe wood handle, because wood planers are disagreeable for me.

Blades are almost complete. Still some edge work to do. Filled and sanded in places. Sanded down the back of the foam to get the annoying pattern off.
 
Re: Fellowship Gimli - The Lord of the Rings

This is so awesome... I just... wow.

great job! cant wait to see how it comes out :)

- - - Updated - - -

Thanks guys!

Not much to report other than I've begun casting the knot work for the cheek guards, and getting ready to cast all the other knot work bits that go around the brim of the helmet. That and I've done more chaining. No photo evidence of that though :p!

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im really curious to know how you did this. it looks fantastic in the end result!
 
Re: Fellowship Gimli - The Lord of the Rings

Question: Has anyone successfully gotten the hatch mark pattern out of the back of the foam? Sanding? Latex layering? I was going to double up the foam, but that would make the blade very thick and unnatural looking. Far more cartoony than I want.

A bit late for this, but I wonder if one couldn't shave off the backside layer of the foam and then glue a layer of craft foam (since they're both eva) cut in the same shape to that surface. I don't know if that would be more trouble or less trouble than sanding the textured side.
 
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