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  1. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 12, 2011, 7:05 AM - New Vegas NCR Veteran Ranger Build #1

    Been working on this for about a month now, and finally decided to log it here on the RPF. I took a few years off of costuming and finally found something that made me want to get back into it, and I hope to have this done by San Diego Comic Con this year.


    Final Result:




    This is the obvious goal.


    Armour is made out of Eva Foam, your basic high impact anti-fatigue floor mat. Stencils are made and printed to the scale I liked, traced onto the foam and cut with an x-acto blade.



    Armour is shaped into form by heating it using a heat gun, then it is pressed against my body for it to take the required shape. The edges are then sanded and smoothed out.


    More armour progress, pieces formed and edges are rounded.


    More armour progress, all pieces formed and edges are rounded.


    More armour progress, all pieces formed and edges are rounded.


    Foam vest is fabricated by gluing the foam armour to it.


    Vest is completed by trimming excess foam.


    Showing off my new armour.


    Although not fixed yet, the collar is cut and placed where it would be likely glued onto the armour.


    Using a soldering iron, I burn damage into the armour. All armour damage is done at random, taking no game images into consideration.


    Using Plasti-Dip, I rubberize the armour in order to seal the foam, making it possible to paint the armour.


    The armour begins its transformation through paint, it is painted a basic silver and will be painted using a liquid masking technique as more layers are placed above it.


    Ordered a set of dummy ammo that will be used in the ammo belt on the costume. This dummy ammo will have the tips painted brass to give it a realistic look to them.


    Dummy ammo shells are masked and the orange tips are airbrushed to be a vibrant copper. The ammunition will undergo a series of methods of weathering to bring more realism to them in a post-apocalyptic world.


    Tips are painted copper and given a satin finish.


    Two standard California flags which are to be used to create the New California Republic's flag.


    New California Republic flag is now a single unit by combining parts of both flags to create one.


    Flat toed cowboy boots


    Pattern and Duck Cloth material purchased, these will be used to make the duster.


    By taking advantage of the Pepakura file, I begin construction immediately out of styrene plastic and gluing the pieces together with Plastruct Plastic Weld.


    More progress on the mask, the mask begins to take shape.


    The back of the helmet that wraps around my head is glued on, but still needs better shaping. Also the raised part of the eyes are assembled, but the top part is still not completed.


    M1 Helmet Liner will be used for the top dome of the NCR Veteran Ranger's helmet, the brim will be trimmed and will have the camera setup located on the side of it.


    Bondo has been laid to fill the seams on top, will be sanded smooth after a layer of fiberglass is placed on the interior of the mask.


    A layer of fiberglass is added to the underside of the mask, it will give extra strength to keep itself from cracking under pressure and to ensure it a long life.





    More progress will come as the costume is worked on!
    Last edited by gcngamer128; Jul 26, 2011 at 1:08 PM.
  2. Member Since
    Feb 2011
    Messages
    37
    Jun 12, 2011, 5:56 PM - Re: New Vegas NCR Veteran Ranger Build #2

    Looks great dude! Good job with the descriptions. +1 for Adventure Time shirt.
  3. Member Since
    May 2011
    From
    Greenville, SC
    Messages
    93
    Jun 12, 2011, 6:14 PM - Re: New Vegas NCR Veteran Ranger Build #3

    This is very nice work. Very cleanly done.
  4. Rebabaluba's Avatar
    Member Since
    Nov 2009
    From
    B.C. Canada
    Messages
    125
    Jun 12, 2011, 6:14 PM - Re: New Vegas NCR Veteran Ranger Build #4

    What an awesome build buddy! Can't wait to see the finished costume.
  5. Sluis Van Shipyards's Avatar
    Member Since
    Jul 1999
    From
    Miamisburg, OH (near Dayton)
    Messages
    13,639
    Jun 12, 2011, 7:45 PM - Re: New Vegas NCR Veteran Ranger Build #5

    Looks pretty sweet so far!

    Man I REALLY want to do this helmet, but I've got a list of Star Wars projects that's a mile long.
  6. Teese's Avatar
    Member Since
    Apr 2011
    From
    Missoula, MT
    Messages
    76
    Jun 12, 2011, 8:41 PM - Re: New Vegas NCR Veteran Ranger Build #6

    Nice work man! I love watching fallout builds come together. NCR rangers are badass!
  7. Formerly cobalt crimson Wes R's Avatar
    Member Since
    Jan 2010
    From
    Western PA
    Messages
    9,996
    Jun 12, 2011, 8:45 PM - Re: New Vegas NCR Veteran Ranger Build #7

    Those coat patterns work well for so many projects they pay for themselves in no time. Looks really good so far.
  8. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 13, 2011, 1:20 AM - Re: New Vegas NCR Veteran Ranger Build #8

    As layers of bondo is sanded off, more bondo is added to thin layers where more is required. The cheek edges are also given a little bit of a flare by adding small pieces of plastic which are sanded down and covered with more bondo, which will be sanded smooth later.

  9. The-Clayster's Avatar
    Member Since
    Jan 2009
    From
    Tucson, AZ
    Messages
    284
    Jun 13, 2011, 2:15 AM - Re: New Vegas NCR Veteran Ranger Build #9

    Good to see some progress on here, Andy. Can't wait to see it at Con.
  10. formerly TD4513 Tk-Devo's Avatar
    Member Since
    Aug 2007
    From
    Phoenix, AZ
    Messages
    221
    Jun 13, 2011, 2:51 AM - Re: New Vegas NCR Veteran Ranger Build #10

    Take that hunk of crap and get it off this forum Andy! <3 Can't wait to see it at con!

    Your friend,
  11. Member Since
    Jan 2011
    From
    England
    Messages
    20
    Jun 14, 2011, 6:03 PM - Re: New Vegas NCR Veteran Ranger Build #11

    looking good so far, the armour is looking pretty sweet i've also been working a veteran ranger costume but i have only been working on the mask, got as far as making a resin cast and smoothing it down
  12. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 15, 2011, 6:31 AM - Re: New Vegas NCR Veteran Ranger Build #12

    nigel123 said: View Post
    looking good so far, the armour is looking pretty sweet i've also been working a veteran ranger costume but i have only been working on the mask, got as far as making a resin cast and smoothing it down
    I'm thinking about molding my mask when I'm done with it. I'd like the ability to have extra copies and perhaps to pass them off to others too.
  13. ginyu force's Avatar
    Member Since
    Jun 2011
    From
    ventura/california
    Messages
    144
    Jun 15, 2011, 4:54 PM - Re: New Vegas NCR Veteran Ranger Build #13

    this is the coolest thing of all time, you should finish it so we can see the rest!
  14. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 16, 2011, 9:31 AM - Re: New Vegas NCR Veteran Ranger Build #14

    I spent the past few days working on the many belts for the costume, glad that I have an account with Tandy Leather. So with the past few days of dying leather, I haven't had time to update with pics, but I'll be beating up the leather after I condition it, and then assemble them.


    Been working really hard on the mask lately, lots of bondo, sanding, rinse, repeat. Will be working on the mouth and breather part (the thing on the side) today.

    Been spending lots of cash on it too, so far I ordered D-Rings and those rectangle fittings to complete the belts, along with an A/V cable for the cheek cord. I also ordered a .45 holster, so that will carry the .45 replica airsoft gun I purchased, I also got my hands on a nickle plated replica of a Colt .45 Single Action Revolver, so that will be my main weapon until I decide whether it's time or not to build the Anti-Material Rifle; considering Eva Foam after I saw the Mass Effect Assault Rifles.



    One item that I can't exactly figure out is what I should use for my flag pole? I figured I'd just go buy some lead pipe and keep it in two sections with a small L fitting holding them together, that way it would be an easy thing to pack up, but then I came to the realisation that lead pipes would be WAY TOO HEAVY for a mobile flag pole. I want to avoid PVC Pipes because they can look pretty corny and are often overused in costumes when a straight cylinder is required for a prop. Does anyone have any suggestions?
  15. Snowmageddon's Avatar
    Member Since
    Feb 2011
    From
    The Thumb of Michigan
    Messages
    29
    Jun 16, 2011, 10:35 AM - Re: New Vegas NCR Veteran Ranger Build #15

    Aluminum pipe isn't overly expensive so perhaps you could use that for your flag pole? Excellent build by the way.
  16. xraydelta99's Avatar
    Member Since
    Jan 2011
    Messages
    36
    Jun 17, 2011, 4:23 PM - Re: New Vegas NCR Veteran Ranger Build #16

    Loving the foam work, actually looking at your pattern has solved an issue that I have been thinking about. once again great work.
  17. Member Since
    May 2011
    From
    Greenville, SC
    Messages
    93
    Jun 17, 2011, 6:52 PM - Re: New Vegas NCR Veteran Ranger Build #17

    After looking at the flag, I have to say that you've done an excellent job. I have no idea how you did it. Looks totally original.
  18. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 18, 2011, 4:45 AM - Re: New Vegas NCR Veteran Ranger Build #18

    xraydelta99 said: View Post
    Loving the foam work, actually looking at your pattern has solved an issue that I have been thinking about. once again great work.
    Thanks for the compliments, but I can't take any credit for the foam armour templates, I took the idea from Kommissar here on the forums. I basically took the image he did of the armour laying flat on the ground and threw it into photoshop, then made templates based on that image, then scaled it to my size.


    Theist17 said: View Post
    After looking at the flag, I have to say that you've done an excellent job. I have no idea how you did it. Looks totally original.
    Thanks for the compliments! I basically took the 2 flags, cut the image off of the other and used silicone convertible top glue/sealant to attach it to the other. For "NEW" I took the "N" and "E" off of the other flag and took the two letters "A" and flipped them upside down and turned them into a "W". I didn't do to great of a job on singeing the edges, but it's passable.
  19. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 19, 2011, 8:08 AM - Re: New Vegas NCR Veteran Ranger Build #19

    Still working hard on the outfit, the mask keeps getting the good ol' Bondo treatment, working on that bulge on the left ear now. Today I hope to start on the two breather pieces, the one on the mouth and the one on the left cheek. Once those are done, I'll be able to prime this thing and prepare it for painting.

    Been conditioning the leather on the belts too, that takes longer than I would have expected. Still waiting on more parts to come in before I can finish the belts, but I hope they come in soon.

    Comic Con is coming up quick, and I'm pushing really hard to get this done!
  20. lou3433 is offline lou3433
    Jun 19, 2011, 8:24 AM - Re: New Vegas NCR Veteran Ranger Build #20

    Great build thread!!

    You could try using some conduit pipe for the flag pole.
  21. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 21, 2011, 6:10 AM - Re: New Vegas NCR Veteran Ranger Build #21

    I create the 3 sections that will come together to form the microphone on the front of the mask. The 3 sections were Plastic Welded together and the seams were covered in Bondo. When they are sanded, they will be glued down, and a mesh insert will complete the interior and create a microphone-like mass.




    Using the Pepakura templates, I cut out the item using styrene plastic. After it was glued on, the item was then fiberglassed to the mask, and then covered with Bondo until I could get a nice round shape to it. It is not yet completed, but is almost there.

  22. Evil Benius's Avatar
    Member Since
    Nov 2009
    From
    Green Lane, PA
    Messages
    82
    Jun 21, 2011, 6:51 AM - Re: New Vegas NCR Veteran Ranger Build #22

    Looking really good so far. I know how annoying it can be to build a costume that has never actually existed in the real world. Someone needs to tell video-game artists to start using more found parts.

    I cannot wait to see the finished project.
  23. gcngamer128's Avatar
    Member Since
    Jan 2011
    From
    Las Vegas, NV
    Messages
    114
    Jun 21, 2011, 7:55 AM - Re: New Vegas NCR Veteran Ranger Build #23

    Evil Benius said: View Post
    Looking really good so far. I know how annoying it can be to build a costume that has never actually existed in the real world. Someone needs to tell video-game artists to start using more found parts.

    I cannot wait to see the finished project.
    You know what's worse? 3 different masks exist.

    1. Cover Art.
    2. Promotional Art.
    3. In Game Model.

    So I'm trying to mix and match what I like best, I'll figure something out
  24. Member Since
    Jan 2011
    Messages
    57
    Jun 21, 2011, 10:16 AM - Re: New Vegas NCR Veteran Ranger Build #24

    awesome work so far. I had heard of the technique of heating and shaping foam for armor but hadn't seen it practiced until now. Looks excellent. This costume should frighten some people for sure!
  25. Arcko's Avatar
    Member Since
    Apr 2011
    From
    El Paso, TX
    Messages
    45
    Jun 21, 2011, 12:07 PM - Re: New Vegas NCR Veteran Ranger Build #25

    Well done so far! I am sure the Kommisar's build probably saved you a ton of heartache on this build. Look forward to seeing more progress shots of the gas mask. I am doing a styrene build right now on some steampunk armor and this little Bondo trick might help me with all the little kinks.

    -Arcko

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