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  1. Member Since
    Aug 2013
    From
    Texas
    Messages
    23
    Aug 13, 2013, 1:39 PM - Elysium HULC (powered exoskeleton) costume #1

    Hello RPF community! This is my first post and my first movie costume build using foam. I saw the trailers for Elysium a few months ago and decided(despite travel and work) to make the HULC(Human Universal Load Carrier) or powered exoskeleton that Matt Damon wears. I started work on it, but couldn't finish in time for the movie's premiere, but I loved the film and it reinspired me to finish it despite my hectic Summer.
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    I'm using the 0.5" EVA foam puzzle-piece "Gold's Gym" equipment mats from Walmart for $20. I'm using a wood-burning wand with an Exacto-blade attachment(as well as others for shaping). Hot glue binds the pieces. I'm using two sizes of PVC to approximate the pistons.
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    That picture shows the chest piece and the upper arm/shoulder segments linked with the PVC pistons(which will get a paint treatment later). The white nylon straps make a harness I can wear under a gray shirt to keep the whole thing in place.
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    That one shows the beginning of the forearm bracers
    Here's the completed forearms:
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    That's all the progress I've made thus far. I'm attaching the bracers to the upper arm pistons today. Tomorrow I begin the spine and head piece. I'll be adding socket-head cap screws to each foam piece for detail along with wires and lights for the head. More pictures to come.
    Is anyone else making one of these?
    PROGRESS UPDATE: (8-14-13)
    It was more problematic linking the forearm bracers to the upper arm sections than I first expected, but once I reinforced the foam with black coat hanger wire it supported itself nicely.
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    Here's a shot of the underside with the completed arms
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    That shows the attached nylon harness and the elbow straps.
    I put the pieces on to demonstrate the working connections and I'm wearing the harness over my shirt to show its fitting as well. I will conceal the elbow straps under gauze wrapping when the whole thing is finished.
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    Try to ignore the stray pistons. I will connect them to the shoulder blades later.
    Thanks again for the support everyone! You guys are awesome.
    UPDATE (8-27-13)
    Before I could begin the spinal section or shoulder blades, I had to construct a duct tape dummy to hold my work:
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    I know it looks crude, but it's my first. :-)
    This plus my day job set back my progress a little. I did start painting and reconstructing new pistons (because I just wasn't happy with the old ones):
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    UPDATE (9-4-13)
    I've nearly finished the head piece:
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    The upcoming wires and mount covers for them will conceal the globulous hot-glue on the edges and I'll install a blue LED on the com-port for the right side of my head.
    Progress was slowed again because I'm remaking all the previous pistons, changing their mounting bolts, and reinforcing the foam where they connect. It's tedious.
    UPDATE (9-11-13)
    I finally finished the head piece and cervical section:
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    I couldn't resist sticking it to my head again:
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    I still need to rig the blue LED+wire to the data port and ribbon cable on the right. I've been sick for the past two days so - delays delays delays, but I WILL start the spine and shoulders tomorrow.
    UPDATE (9-12-13)
    I finished the shoulder blades:
    Click image for larger version. 

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    I had to stop work on the spine section to fix some problems with a few pistons, bolster the harness a little, and begin replacing the bolts and stop nuts being used to attach the pieces to the harness with magnets. Thanks to Demolition for the magnet idea - "... then attach the armour through the shirt with earth magnets ..." Soooo much better than unscrewing bolts each time I need to make an adjustment. I'm feeling foolish for using bolts now.

    I didn't realize there was a picture limit for each post, so I'm submitting updates through replies now. I'm getting with the program, finally.
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    Last edited by Odayaka; Oct 29, 2013 at 5:15 PM.
  2. rolandblais's Avatar
    Member Since
    Jul 2013
    From
    Fernley, NV
    Messages
    129
    Aug 13, 2013, 2:06 PM - Re: Elysium HULC (powered exoskeleton) costume #2

    That's Awesome! If I wasn't so deeply invested in my Dredd costume I'd start another project... Maybe next year. I look forward to your updates!
  3. The Irish Cowbo's Avatar
    Member Since
    Apr 2013
    From
    Chelmsford, Massachusetts, United States
    Messages
    37
    Aug 13, 2013, 2:28 PM - Re: Elysium HULC (powered exoskeleton) costume #3

    Yeeeeeeeeaaaa here we go! Looking awesome! Subbed'
  4. The martin's Avatar
    Member Since
    Aug 2013
    Messages
    67
    Aug 13, 2013, 2:29 PM - Re: Elysium HULC (powered exoskeleton) costume #4

    Such an awesome idea! I'm loving it. Can't wait to see what you do to finish it.
  5. Member Since
    May 2013
    Messages
    10
    Aug 13, 2013, 2:31 PM - Re: Elysium HULC (powered exoskeleton) costume #5

    looks great. can't wait to see more
  6. Scarlet Swashbuckler RPF Premium Member Sundowner's Avatar
    Member Since
    Jan 2010
    From
    Shadow
    Messages
    5,766
    Aug 13, 2013, 2:54 PM - Re: Elysium HULC (powered exoskeleton) costume #6

    Subscribed! Looking great so far!
  7. Member Since
    Sep 2012
    From
    Santa Clara, Ca
    Messages
    288
    Aug 13, 2013, 7:43 PM - Re: Elysium HULC (powered exoskeleton) costume #7

    AWESOME!!!!
  8. The Law RPF Premium Member Rikarus's Avatar
    Member Since
    Oct 2010
    Messages
    845
    Aug 13, 2013, 7:57 PM - Re: Elysium HULC (powered exoskeleton) costume #8

    subscribed!!!!
  9. RPF Premium Member made007's Avatar
    Member Since
    Sep 2011
    From
    Puerto Rico
    Messages
    1,392
    Aug 14, 2013, 1:05 AM - Re: Elysium HULC (powered exoskeleton) costume #9

    Ill follow this one close, because i want to make one too
  10. Rysjin7717's Avatar
    Member Since
    Feb 2011
    From
    In Th' wheat fields somewhere in Dorothy land
    Messages
    939
    Aug 14, 2013, 1:37 AM - Re: Elysium HULC (powered exoskeleton) costume #10

    Subbed look forward to your progress looks great so far.
  11. Member Since
    Aug 2013
    From
    Texas
    Messages
    23
    Aug 15, 2013, 12:59 AM - Re: Elysium HULC (powered exoskeleton) costume #11

    Thanks to everyone for the responses! I'm brand new here and honestly didn't expect many comments, but it's obvious I'm not the only one interested in the Elysium HULC costume. I knew I wanted to try making it the first time I saw the trailer and I'm having a blast so far.
    Last edited by Odayaka; Aug 15, 2013 at 11:46 AM.
  12. Honus's Avatar
    Member Since
    Jul 2003
    From
    Colorado
    Messages
    673
    Aug 15, 2013, 12:04 PM - Re: Elysium HULC (powered exoskeleton) costume #12

    That's awesome! I very much want to make one of these suits.
  13. aeonpulse's Avatar
    Member Since
    Dec 2011
    From
    LV-426
    Messages
    1,517
    Aug 15, 2013, 2:06 PM - Re: Elysium HULC (powered exoskeleton) costume #13

    This is looking great! Really excited to see how this turns out!
  14. Getoninja's Avatar
    Member Since
    Aug 2007
    From
    The Deadzone aka Los Banos, CA
    Messages
    249
    Aug 16, 2013, 12:29 PM - Re: Elysium HULC (powered exoskeleton) costume #14

    amazing job so far. But if you need more reference pictures the Exo skeleton is on Ebay
    Elysium Max Da Costa Matt Damon Screen Worn Hard Stunt Weta Hulc Suit Prop Set | eBay
  15. Member Since
    Aug 2013
    From
    Texas
    Messages
    23
    Aug 17, 2013, 1:25 AM - Re: Elysium HULC (powered exoskeleton) costume #15

    Getoninja said: View Post
    amazing job so far. But if you need more reference pictures the Exo skeleton is on Ebay
    Elysium Max Da Costa Matt Damon Screen Worn Hard Stunt Weta Hulc Suit Prop Set | eBay
    Thank you so much for finding that. I've been looking around for more reference material. The photos from that listing are the best I've seen yet...without paying for the "Art of Elysium" book. Those pics are going on my "reference board" in front of my work table. Just in time too, I'm about to start the spine section!

    Thanks again!
  16. RPF Premium Member Bayouwolf's Avatar
    Member Since
    Jan 2013
    From
    Long Beach, CA
    Messages
    374
    Aug 17, 2013, 10:55 AM - Re: Elysium HULC (powered exoskeleton) costume #16

    Great build. The wifey and I just saw this the other day and I'm putting a Kruger hard-suit (The one he wears at the end of the film) on my to-build list.
  17. Purveyor of Justice RPF Premium Member Gary Pahls's Avatar
    Member Since
    Jul 2011
    From
    Novi, Mi
    Messages
    291
    Aug 17, 2013, 10:34 PM - Re: Elysium HULC (powered exoskeleton) costume #17

    I was wondering when someone was going to try this but I really didn't think the first horse out of the gate was going to be to this level; great job!
  18. hardreplic's Avatar
    Member Since
    Oct 2010
    From
    Guarulhos, São Paulo, Brasil.
    Messages
    43
    Aug 18, 2013, 6:20 AM - Re: Elysium HULC (powered exoskeleton) costume #18

    I really liked your idea, I was following the Internet the concept of this movie, but my interest is in the robots.
    I want to see it done soon, good luck!
  19. formerly tardis55
    Member Since
    Jun 2006
    From
    USA
    Messages
    808
    Aug 19, 2013, 2:41 AM - Re: Elysium HULC (powered exoskeleton) costume #19

    Be careful. The one on ebay has many pieces missing and is assembled wrongly.
  20. Jeebee25's Avatar
    Member Since
    Dec 2011
    From
    Chicago, IL
    Messages
    110
    Aug 25, 2013, 11:59 AM - Re: Elysium HULC (powered exoskeleton) costume #20

    Well done! My friend and I were thinking of doing a pair of these and it occurred to me that someone was probably already on it! Thread = subscribed!
  21. Member Since
    May 2010
    From
    Queensland, Australia
    Messages
    194
    Aug 26, 2013, 12:27 PM - Re: Elysium HULC (powered exoskeleton) costume #21

    So damn cool! Definitely on my to build list
  22. DarthWad3r's Avatar
    Member Since
    Nov 2011
    From
    Florida
    Messages
    74
    Aug 26, 2013, 12:35 PM - Re: Elysium HULC (powered exoskeleton) costume #22

    Awesome. I'm hoping to see a costume similar at dragon con. Keep up the good work!
  23. Demolition's Avatar
    Member Since
    Aug 2011
    From
    Grimsby UK
    Messages
    268
    Aug 26, 2013, 12:46 PM - Re: Elysium HULC (powered exoskeleton) costume #23

    nice build man its looking really nice, ive just been looking at your pics and if you made a sub frame you could hide the straps and make it look more like the screen used one make harness with the straps fit to body first then put on shirt and then attach the armour through the shirt with earth magnets or with velcro through holes in the shirt just an idea looks ace well done
  24. RPF Premium Member kevinericon's Avatar
    Member Since
    Jun 2006
    Messages
    504
    Aug 26, 2013, 8:00 PM - Re: Elysium HULC (powered exoskeleton) costume #24

    It looks promising. Can't wait for more!
  25. Member Since
    Aug 2013
    From
    Texas
    Messages
    23
    Aug 27, 2013, 2:24 AM - Re: Elysium HULC (powered exoskeleton) costume #25

    I'm glad you like what I've done so far - Demolition. The harness is already sized to fit under a T-shirt. The current design literally bolts to the harness. The gray shirt will get sandwiched between the costume and the harness. The plan was to push the bolts through precut holes in the shirt, but I am considering alternate methods to attach the costume. I like the idea of magnets. :-)

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