Half-life 2 Combine Elite (Updated June 9th) Home Stretch!

hlo · 05-22-2009, 03:34 AM

Hello Everybody
First time posting with a real project :P
The costume is a "Combine Elite" from the video game Half-life 2.
I'm trying to complete this in spare time from my full time job to be ready for a convention on June 12-14 in Vancouver so I am sculpting/sewing my ass off.
This is sculpting session number two. Just getting a feel for water-based clay (only worked in sculpey and plastiline). I will do a two part hydrocal/plaster mold then do a white gel-coat and cast it in fiberglass. Now for some low res pictures :P

This clay is wonderful to work with, smooths like butter and chocolate icing.

I admit its still very rough state.

edit:
Heres the character rendered

TKDUEUNO · 05-22-2009, 06:29 AM

Awesome!

I'm doing a Metrocop costume, used pepakura for the helmet.
I wanted to do the Elite too, but gave up because with the right proportions and dimensions the wearer's eyes fall under the big red eye of the helmet so you can't see a thing, I'm curious to see how you address that

I thought about putting a small cam and screen glasses, it can be done.

I'll follow your progress!!!

Ghost Host · 05-22-2009, 02:02 PM

Pretty cool. I was thinking of doing a standard Combine soldier at some point. Can't wait to see your costume progress!

Chronos · 05-22-2009, 02:05 PM

The Combine soldiers have such a great look.

Awesome, man! Can't wait to see your progress.

hlo · 05-22-2009, 10:24 PM

Thanks guys for the compliments. For seeing with this helmet I'll try doing some pinholes for seeing through. Either that or work off this technique for hiding cameras (replace the camera with my eye).

Amish Trooper · 05-23-2009, 03:21 PM

Look forward to this build especially being a half-life fan

hlo · 05-25-2009, 12:03 AM

Update:

Just started sewing the flack-jacket/ ballistic vest. I never knew sewing took so long. Oh the humanity! Well I went out and bought some white nylon fabric and some one inch foam for the padding. Here's the result so-far.

The dark marks are charcoal I used. From the material file I extracted from the game, the character is quite dirty. So no worries about keeping any of the fabric clean (well as long as I don't spill bright fluorescent pink all over everything) and I'll be good.

Kwally89 · 05-25-2009, 12:30 AM

Man, this is going to be cool! HL2 is one of my all time favorite pc games!! Keep it up!

EyeintheSky · 05-25-2009, 04:25 AM

Cool project, can't wait to see the final result!

boodha · 05-25-2009, 10:13 PM

Looks good so far. looking forward to updates

hlo · 05-26-2009, 11:34 PM

Well I've started on the armor plating parts (the codpiece is shown here in particular). I sculpted on a slab of melanite (sometimes you see cabinets made of this stuff) and then I molded it in some DAP plaster of paris. To release it from the board I just ran the hose on it for a few seconds allowing the water to work its way between the mold and the board.

I'll be reusing the clay (hey who isn't cheap?). Now to just let the plaster set up overnight then I can do some touchups, sand it smooth, add a coat of sealer, then get onto gelcoating and fiber glassing this baby right up.
edit: Forgot to add that I'll be adding the ridges shown in the character photo after by gluing on some strips of styrene.

hlo · 05-27-2009, 10:42 PM

I've decided to add the ear and gas mask pieces separately because its easier. This is adding some flashing to split the mold in half.

And here is the mold completed (patching up some holes with wood-filler).

Now onto clearcoating !

Kwally89 · 05-28-2009, 03:10 PM

You're doing some interesting things as far as molding and casting goes. I'm excited to see the first pull. Keep it coming buddy!

MisriahArmory · 05-31-2009, 10:08 PM

Damn, I dig this project! Did you use any release agent on the master?

hlo · 06-02-2009, 09:54 PM

LastSpartan: Nope, no release agent. It came out nice and fine though.

Haven't been on for a few days, hurt myself at work and I am waiting for workers comp to accept my claim. I've been scrounging together money to try and finish this project. I've decided to switch from fiberglass to styrene for the leg and arm armor because it requires less time and is cheaper. Still need to fill a few holes on the helmet. Please ignore the rough part in the front. I need to sculpt the gas-mask part and ear thingies on still. I'll be molding them with some polyurethane rubber I have kicking around. I'll try to make that piece detachable with some magnets if I have the time.
Now for pictures!

Any tips on cutting / shaping styrene would be appreciated. Though I'll use the search feature first.

Kadajiroth · 06-03-2009, 09:52 AM

Awesome work so far, bud. I love the Half-Life 2 Combine soldiers, I've always wanted to make their armor. Keep it up.

Yodajammies · 06-03-2009, 12:21 PM

What kind of plaster/molding material are you using there? Every past usage of plaster as a mold has ended in tears. I assume this is not your everyday "plaster of paris" ?

hlo · 06-08-2009, 05:44 AM

Almost at the homestretch!
I will be repainting the lines on the helmet, they seem too thick to me. I also need to use some cheesecloth to stencil some black paint on the grey parts, and I need to attach the neodymium magnets so the gas mask stays on/ detaches. The eye I am going found item shopping tomorrow for parts.

Also did some work on the armor.

hlo · 06-08-2009, 05:46 AM

Yodajammies: The plaster I used that came in contact with the plug is called "hydrocal" its a harder, concrete-like plaster. Then I put regular plaster of paris reinforced with cheesecloth and burlap.

hlo · 06-09-2009, 04:54 AM

Well I'm done all the physical fabricating now just onto sewing.

Here's a macro shot of the result of using cheesecloth as a stencil with (and without) flash.

The eye is wired up with two red LED's.

Contec · 06-09-2009, 05:20 AM

What did you use for the eye lense?

hlo · 06-09-2009, 05:36 AM

I found some two piece clear acrylic christmas bulb type things at the craft store. I bought two of different sizes and glued them together and cut them to size.

Kwally89 · 06-11-2009, 05:08 PM

Wow! This has been really fun to follow! I can't wait to see it all done. The eye looks great, btw.

Kody

Tiki · 06-11-2009, 11:39 PM

Looks great - but I still don't get how you are gonna see out of this thing!

Ghost Host · 06-12-2009, 10:37 AM

pretty cool!

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05-22-2009, 03:34 AM	#1
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Half-life 2 Combine Elite (Updated June 9th) Home Stretch! Hello Everybody First time posting with a real project :P The costume is a "Combine Elite" from the video game Half-life 2. I'm trying to complete this in spare time from my full time job to be ready for a convention on June 12-14 in Vancouver so I am sculpting/sewing my ass off. This is sculpting session number two. Just getting a feel for water-based clay (only worked in sculpey and plastiline). I will do a two part hydrocal/plaster mold then do a white gel-coat and cast it in fiberglass. Now for some low res pictures :P This clay is wonderful to work with, smooths like butter and chocolate icing. I admit its still very rough state. edit: Heres the character rendered Last edited by hlo; 05-22-2009 at 03:37 AM. Reason: forgot something

05-22-2009, 06:29 AM	#2
TKDUEUNO Join Date: Jun 2008 Posts: 109 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Awesome! I'm doing a Metrocop costume, used pepakura for the helmet. I wanted to do the Elite too, but gave up because with the right proportions and dimensions the wearer's eyes fall under the big red eye of the helmet so you can't see a thing, I'm curious to see how you address that I thought about putting a small cam and screen glasses, it can be done. I'll follow your progress!!! Last edited by TKDUEUNO; 05-22-2009 at 06:36 AM.

05-22-2009, 02:02 PM	#3
Ghost Host Join Date: Jul 2002 Location: California Posts: 3,055 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Pretty cool. I was thinking of doing a standard Combine soldier at some point. Can't wait to see your costume progress!

05-22-2009, 02:05 PM	#4
Chronos By Your Command Join Date: Jun 2008 Location: Chicagoland Posts: 735 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite The Combine soldiers have such a great look. Awesome, man! Can't wait to see your progress.

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05-22-2009, 10:24 PM	#5
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Thanks guys for the compliments. For seeing with this helmet I'll try doing some pinholes for seeing through. Either that or work off this technique for hiding cameras (replace the camera with my eye). Last edited by hlo; 05-22-2009 at 10:25 PM. Reason: change layout

05-23-2009, 03:21 PM	#6
Amish Trooper Steven C. Join Date: Jan 2009 Location: Michigan Posts: 1,760 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Look forward to this build especially being a half-life fan

05-25-2009, 12:03 AM	#7
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Update: Just started sewing the flack-jacket/ ballistic vest. I never knew sewing took so long. Oh the humanity! Well I went out and bought some white nylon fabric and some one inch foam for the padding. Here's the result so-far. The dark marks are charcoal I used. From the material file I extracted from the game, the character is quite dirty. So no worries about keeping any of the fabric clean (well as long as I don't spill bright fluorescent pink all over everything) and I'll be good.

05-25-2009, 12:30 AM	#8
Kwally89 Join Date: Jun 2008 Location: Iowa Posts: 396 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Man, this is going to be cool! HL2 is one of my all time favorite pc games!! Keep it up!

05-25-2009, 04:25 AM	#9
EyeintheSky Join Date: Jun 2008 Location: Milan, Italy Posts: 135 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Cool project, can't wait to see the final result!

05-25-2009, 10:13 PM	#10
boodha Join Date: Nov 2006 Location: fukudipsht Posts: 319 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Looks good so far. looking forward to updates

05-26-2009, 11:34 PM	#11
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite Well I've started on the armor plating parts (the codpiece is shown here in particular). I sculpted on a slab of melanite (sometimes you see cabinets made of this stuff) and then I molded it in some DAP plaster of paris. To release it from the board I just ran the hose on it for a few seconds allowing the water to work its way between the mold and the board. I'll be reusing the clay (hey who isn't cheap?). Now to just let the plaster set up overnight then I can do some touchups, sand it smooth, add a coat of sealer, then get onto gelcoating and fiber glassing this baby right up. edit: Forgot to add that I'll be adding the ridges shown in the character photo after by gluing on some strips of styrene. Last edited by hlo; 05-26-2009 at 11:38 PM. Reason: Ich hat vergessen.

05-27-2009, 10:42 PM	#12
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated May 26th) I've decided to add the ear and gas mask pieces separately because its easier. This is adding some flashing to split the mold in half. And here is the mold completed (patching up some holes with wood-filler). Now onto clearcoating !

05-28-2009, 03:10 PM	#13
Kwally89 Join Date: Jun 2008 Location: Iowa Posts: 396 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated May 26th) You're doing some interesting things as far as molding and casting goes. I'm excited to see the first pull. Keep it coming buddy!

05-31-2009, 10:08 PM	#14
MisriahArmory formerly LastSpartan Join Date: Jun 2008 Posts: 140 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated May 26th) Damn, I dig this project! Did you use any release agent on the master?

06-02-2009, 09:54 PM	#15
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated May 27th) LastSpartan: Nope, no release agent. It came out nice and fine though. Haven't been on for a few days, hurt myself at work and I am waiting for workers comp to accept my claim. I've been scrounging together money to try and finish this project. I've decided to switch from fiberglass to styrene for the leg and arm armor because it requires less time and is cheaper. Still need to fill a few holes on the helmet. Please ignore the rough part in the front. I need to sculpt the gas-mask part and ear thingies on still. I'll be molding them with some polyurethane rubber I have kicking around. I'll try to make that piece detachable with some magnets if I have the time. Now for pictures! Any tips on cutting / shaping styrene would be appreciated. Though I'll use the search feature first. Last edited by hlo; 06-02-2009 at 10:15 PM.

06-03-2009, 09:52 AM	#16
Kadajiroth Join Date: Nov 2006 Location: Perth, Australia Posts: 1,725 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 2nd)) Awesome work so far, bud. I love the Half-Life 2 Combine soldiers, I've always wanted to make their armor. Keep it up.

06-03-2009, 12:21 PM	#17
Yodajammies Join Date: Jun 2008 Location: NashVille, TN Posts: 240 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 2nd)) What kind of plaster/molding material are you using there? Every past usage of plaster as a mold has ended in tears. I assume this is not your everyday "plaster of paris" ?

06-08-2009, 05:44 AM	#18
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 2nd)) Almost at the homestretch! I will be repainting the lines on the helmet, they seem too thick to me. I also need to use some cheesecloth to stencil some black paint on the grey parts, and I need to attach the neodymium magnets so the gas mask stays on/ detaches. The eye I am going found item shopping tomorrow for parts. Also did some work on the armor.

06-08-2009, 05:46 AM	#19
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 2nd)) Yodajammies: The plaster I used that came in contact with the plug is called "hydrocal" its a harder, concrete-like plaster. Then I put regular plaster of paris reinforced with cheesecloth and burlap.

06-09-2009, 04:54 AM	#20
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 8th)) Well I'm done all the physical fabricating now just onto sewing. Here's a macro shot of the result of using cheesecloth as a stencil with (and without) flash. The eye is wired up with two red LED's.

06-09-2009, 05:20 AM	#21
Contec Join Date: Jun 2008 Location: leave this spoof site and go to www dot the replica prop forum dot com Posts: 2,441 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 8th)) What did you use for the eye lense?

06-09-2009, 05:36 AM	#22
hlo Join Date: Jan 2009 Location: Canada Posts: 40 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 9th) Home Stretch! I found some two piece clear acrylic christmas bulb type things at the craft store. I bought two of different sizes and glued them together and cut them to size.

06-11-2009, 05:08 PM	#23
Kwally89 Join Date: Jun 2008 Location: Iowa Posts: 396 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 9th) Home Stretch! Wow! This has been really fun to follow! I can't wait to see it all done. The eye looks great, btw. Kody

06-11-2009, 11:39 PM	#24
Tiki Join Date: Dec 2007 Location: Kailua, Hawaii Posts: 74 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 9th) Home Stretch! Looks great - but I still don't get how you are gonna see out of this thing!

06-12-2009, 10:37 AM	#25
Ghost Host Join Date: Jul 2002 Location: California Posts: 3,055 Thanks: 0 Thanked 0 Times in 0 Posts	Re: Half-life 2 Combine Elite (Updated June 9th) Home Stretch! pretty cool!

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