Batman v Superman - Mech Suit_Halloween Costume 2015

Kaver84 · Oct 9, 2015

I decided to make the Batman mech suit from the upcoming Batman v Superman movie. I'm starting later than I had hoped so is going to be a fast build, but fast doesn't mean I'm going to slack on awesomeness. I figured posting a thread will keep me motivated. I'm using a mix of pep files from Kadzaneon and free hand to increase detail in some areas. Pictures to follow.

Kaver84 · Oct 9, 2015

So I converted the pep helmet file into a 3D printable file. I split it up to fit my build volume and reduce print times. After printing I glued the sections together. Then added fiberglass tape to the seams and first layer of bondo short strand to increase strength. I've sanded the first layer and have added regular bondo for the second layer. One more pass sanding and the helmet should be in good shape. Next step is scaling the other files and making EVA pieces. I add pictures as I go.

Kaver84 · Oct 9, 2015

First and second Layer of Bondo

Kaver84 · Oct 9, 2015

Not sure whats up with the photos being sideways.... They're right going in but that's how they show up, sorry. I also decided to make a batarang. This one I modeled myself based off of images from the Arkham Asylum game. I designed them with earth magnets so they snap open and closed. I'll try to post a video later. Gray batarang glows blue in the dark. I'll paint them to look metallic and battle hardened. I'll scuff the edges on the glow in the dark one so the glowing effect will be on the edges.

SuperHero · Oct 10, 2015

Cool stuff. Very creative.

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Kaver84 · Oct 10, 2015

Progress pics. Forearm, bicep, and shoulder. Not super clean but I'll fix it with plasti-dip and battle damage. I'm in the process of 3D printing the elbow hinges. Tomorrow will be chest and leg. Maybe a duck tape mannequin as well for display/scaling purposes.

Kaver84 · Oct 10, 2015

Here are my last two costumes. The goal is to improve every year. I have a ton of pictures so if anyone wants to see a separate thread of the build I can certainly make one.

Kaver84 · Oct 11, 2015

Batarang video

[video]https://youtu.be/ED79pxh4WoY[/video]

gothic · Oct 12, 2015

looking good and your no stranger to armour builds, look forward to its progress

Armatus Cosplay · Oct 12, 2015

Is there a reason you didn't clean up the helmet model and increase the wall thickness prior to printing so it wouldn't need any additional smoothing work or internal support? Almost seems like working backwards to 3d print a helmet that needs a ton of additional work to get to the finished piece anyway.

That being said it looks great, so keep that up :thumbsup

Kaver84 · Oct 12, 2015

Thank you! I'll have more pictures tomorrow

Kaver84 · Oct 12, 2015

All good questions about the helmet. I used pla for the prints to avoid warping. Its difficult to get a good bond with glue on pla. There's also layer lines on the finished product. The bondo is is being used as a reinforcement and smoothing agent. It literally took 10 minutes with course sandpaper to smooth out the rough first layer. Second layer with be even easier and its done. Still way way easier than pep and fiberglass resin.

Kaver84 · Oct 13, 2015

Today I got the chest/back piece created as well as a thigh and shin. I had some trouble with my hot glue not sticking well, not sure if it has absorbed to much moisture or what the deal is. Some of the seams suffered because of it. I can fix it with some strategic battle damage and a good paint job. So far everything is fitting well. I'm hoping to get a duck tape dummy made soon so I can see the overall scale. I just need to talk my wife into taping me up. I also worked on some helmet electronics tonight and sampled some paint schemes. More to come.

Shocktrooper28 · Oct 13, 2015

Awesome!

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Kaver84 · Oct 20, 2015

More progress pics. Arms, legs, chest, and cod are complete. Abs are next. Helmet needs final sanding. I plan on 3D printing the elbow and knee hinges. I am also going to print the gloves using ninjaflex. Thats going to happen this weekend while I'm painting the rest of the suit. I'll add another pic of the abs and cod tomorrow.

Kaver84 · Oct 23, 2015

Some more progress. Working on some of the hinges and details before paint. Still need to finish sanding the helmet. Tomorrow should be a good day for progress. I dont have pics yet, but I have updated the abs and shins a bit to have more detail.

StarksWarehouse · Oct 26, 2015

Looking great! where did you get the files from?

Kaver84 · Oct 28, 2015

I found the files on the RPF. They were created by Kadzaneon. I also made some of my own files, forearms, for example, just to match the movie version a it better. Not going for 100% accuracy as its just a quick build for Halloween. I have everything in paint right now and its looking good. I'll add more pics once i get done, should be tomorrow or Friday.

Kaver84 · Oct 30, 2015

Here are a few more pics of the helmet after some final sanding and battle damage. I'm currently 3D printing an adjustable bracket for the eyes that holds an electroluminescent ribbon so i can have the glowing effect. The adjustable part is so i can increase and decrease the space below the ribbon for ease of seeing, more light for cool effect, more gap for easier moving around. I'll post a pic when its done. The rest of the suit is also painted, i just need to put it on the dummy and I'll take some pics of that as well.

Tumbler · Oct 30, 2015

Very nicely done. The helmet looks great. Looking forward to seeing the rest painted up. This is going to be my next build so I love to see other examples.

Batman v Superman - Mech Suit_Halloween Costume 2015

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