Age of Ultron Captain America Build (Build complete! pics on page 5)

Discussion in 'Marvel Costumes and Props' started by brutuswayne, Jun 26, 2015.

  1. brutuswayne

    brutuswayne Active Member

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    Hey everyone! So, I've been patterning my AoU Cap suit for the past 2 weeks or so and thought it'd be fun to document the whole process as I make it! I've been sewing and crafting for about 2 years now, but this is my first time building something as detailed and labor intensive as Cap's suit from AoU. This'll be my second MCU cosplay though as I did his Rescue Bucky outfit from TFA two years ago, actually lurked on here for a bit to figure out how to paint my shield. Anyway, I'll just be regularly posting pictures of my progress from pattern to completion, any tips or advice anyone might have is definitely welcome! I'm basing my build method off of the writeup that Sean at SMP Designs did (I think he might actually have an account here somewhere) whose been massively helpful is telling me which fabrics he used, appropriate yardage, and a few other bits of info. But there'll probably be some deviation as well as I go through the construction and find my own way. Also gonna be purchasing pretty much all the hardware (arm magnets, belt buckle, harness bracket, kneepads, etc) from casters that I've found through facebook and etsy since my casting skills are just above novice at best. Anyway, I'll stop blabbering and just get to the pictures, I just finished the pants and pocket pattern last night and I'm really proud of how they ended up coming out! There's a couple out of place lines and tracings all over them that are just from me figuring things out and making adjustment from initial drafts so I might retrace them one last time to have mistake free pattern pieces.

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  2. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Had two friends do a duct tape wrap on my body to make the pattern for the top of the cap suit and went shopping for my fabrics this weekend. Splitting the top into an undershirt with sleeves and an overshirt for all the chest, stomach and back pieces. Hopefully I'll be able to get all of that patterned by the end of the week so I can start sewing ASAP. Also thought I'd show you guys all the swatches I had gathered before buying my fabrics, in total there were about 35 different ones from I think 7 stores. Definitely worth the effort to get the color coordination/matching that I wanted though! Didn't make it to the store that had the brown pleather I chose before they closed though, gonna try and pick that up this weekend.

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  3. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Bit of a silly (but helpful) thing I did during my lunch break. I started roughing out the pattern for the 'overshirt' last night and used MSPaint to traceout a more cleaned up version of the pattern that to gauge where everything should be proportionally. Figured out that I placed the star too low, might actually raise it even higher than what I did in the tracing.

    torso final.jpg
     
  4. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Hey man! Good to see the thread on here - looking great so far and I can't wait to see it progress. Cheers!
     
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  5. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Hey! I knew you had an account on here somewhere! haha. Thanks a lot man, really wouldn't have gotten off the ground without your help!

    Also forgot I had more images to dump into here! Finished (well, kind of) overshirt pattern, and really rough first draft of the arm. Thinking of doing the shoulder and forearm parts as separate pieces that sit on top of the sleeves as opposed to being an actual part of it. Noticed in a lot of shots of the suit, the shoulders floats a little bit at the bottom edge and the forearm guard has a strap, so doing them separate would mean a bit more mobility and easier placement of all the parts in proportion to eachother.
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  6. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Yeah, I know a lot of people are doing the suits with the shoulder separate. The mock ups are looking good!
     
  7. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks! Just a small update this time. Slice apart the arm and torso mockups to adjust the fit at the shoulder. I raised my arm too much during the wrapping so I needed to add some more tape so that the arm could hang down naturally. I also got the idea to get two 1" shoulder pads to make the shoulders a bit bigger, since my shoulders are disproportionally narrow compared to the rest of my arms. One went into the armhole, extended to the appropriate length. The other I put in the top of 'sleevecap' and cut it to match the curvature of the shoulders. Then I just taped it together to make sure it fit the way I want, and then cut it apart at my new seamline. Also added another layer of tape to the arm so that I could redraw everything on a clean pattern. And so I could mess around on snapchat. The red lines show roughly where the arm and armhole originally ended.

    arm.jpg undershirt.jpg joke.jpg
     
  8. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Nice job adjusting your sleeve! Once you true-up those curves in the armscye and the sleeve cap and straighten that shoulder seam, you're going to have an awesome pattern. Cheers!
     
  9. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks! And yeah I spent my whole weekend transferring all that to muslin, adjusting the armscye and sleeve cap curves and then transferring it all to pattern paper. Having a pad underneath the actual shoulder pad, and having that pad sit on top of the jumbo spandex sleeve/sleevecap definitely threw a bit of a kink into figuring out how to sew it all into the armscye, but I think I worked out a way to lock it all together! Unfortunately, was working so rapidly that I forgot to take pictures of all that, hopefully I'll have something to show in a day or two since I'm gonna start actually sewing the undershirt together tonight after work.
     
  10. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Finally got to start sewing last night! Only got the shoulder covers for the undershirt done since I had to spend a lot of time fiddling with scraps to get a feel for the fabrics and get the tension right but it feels good to finally get behind the machine again! They've actually got a really nice curve to them because of the way the pieces were cut so that'll be nice to show once I assemble more of the undershirt tonight and can throw it on the mannequin for pics :) Also, the extended seam allowance on the edge is a little experiment I'm trying for attaching the shoulder armor and the sleeve. The 1" shoulder pads I was talking about before, I want to see if I can install those behind the shoulder armor, but on top of the spandex sleeve. The extra seam allowance will let me sew the 'armor' to the red vinyl, and then sew the spandex sleeve to the edge of the vinyl that's below the padding. It'll make a bit more sense one I sew it all together and can show what I mean.

    shoulder pieces.jpg
     
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  11. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Made some good progress in the past 2 days, attached the shoulder panels to the side jumbo spandex panels, the back cordura piece and topstitched all the seams I've done so far. Also used some spandex to make "pockets" to hold the shoulder padding in place and to give something for the spandex sleeve cap to be sewn too. Now I don't have to do a convoluted system of sewing the shoulder cap and the sleeve to different parts of the red vinyl! Hoping I can get the front pieces and zipper attached by tomorrow night so I can start on the arms this weekend! Also, forgive the weird dust speckles in the picture. Had to use flash since my dining room lighting is awful.

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  12. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Got my shield blank from phebert and star and bracket/handle kit from Valor in the mail yesterday! Sadly won't be able to bring the shield with me to New York Comic-Con in October seeing as their weapons policy is a lot stricter now, but I'll get plenty of use out of the finished shield at a couple other cons I've got in the Fall!

    11700571_565114016980632_2951256943846598091_o.jpg
     
  13. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Finished the body of the undershirt last night, gonna get started on the sleeves tonight! Collar's too big but should be fine seeing as it's covered.

    undershirt.jpg
     
  14. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Looking good, man - keep it up!
     
  15. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks man! Couple more pics, got the shoulder pieces constructed/semi-attached to the undershirt. Added headliner foam to the pleather ring as well so that it'd be reinforced like cordura center. They're not as contoured as I thought they would be so I'm probably gonna end up attaching the bottom edge to the spandex sleevecap after all. Won't get the comfort of a floating piece, but it'll conform to an actual curve way better. Gonna try and get the sleeve cap and bicep sections done today so I can set all that plus the 'wings' of the sleeve cap into the armscye.

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  16. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    It may not look like much, but this was about 4.5 hours of work in one go :p I wish I had taken more pictures of the internals before I sewed them shut though. Essentially, both the shoulder piece and the 'sleeve-cap' are two layers. The outer layer would be the pleather and cordura pieces, the inner layer is just jumbo spandex. Inbetween those is headliner foam and 1" shoulder pads that are cut to shape. The outer pieces are stitched together at the top seam, then the spandex sections are stitched together at the top, and then I stitched both layers together around the armscye to get it all as one section. Result is really solidly padded shoulders that added a bit more size and curvature!


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  17. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Proportions look good, I like the addition of the padding. Great work so far! :)
     
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  18. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks man! Yeah getting those proportions right is definitely tough, part of why I'm glad the stretch of the spandex and ponte give me some room for adjustments after I've cut the pieces :D
     
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  19. Jeck13500

    Jeck13500 Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    looks great ! Not newbie at all !
     
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  20. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Haha thanks! And well I guess newbie was a bit misleading of a word for me to use :p I've been sewing for a little under 2 years now, but this is the first time I've attempted something this complex. !
     
  21. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Bicep sections are done! This actually took a lot longer than I thought! I guess I underestimated how long it'd take to stitch those 3 pieces together and topstitch all of it haha. Gonna see if I can get the spandex below the elbow, the elbow pad, and the forearm guard all assembled into one pieces so I can attach it to the sleeves all at once.

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  22. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Big photodump time! I've been working almost non-stop today since I woke up (and for a few hours last night) and am taking a break before banging out the last 2 hours of work left on the left sleeve. But here's all the stuff I got done on the right sleeve!

    I originally patterned out flat elbow pads, but decided I wouldn't be happy with the look. So I re-patterned them to be domed, made those, and attached them to spandex base for the forearm. They get pulled more taut when I wear it which eliminates the puckering you can see.

    Then I took a crack at making that small pleather section an insert as opposed to making it a section that goes all the way to edge and was really happy and surprised that it came out as good as it did!

    Then I made the actual forearm armor, reinforced it with headliner and topstitched it to the spandex base. I left the bottom edge off the spandex though so that I could insert some more foam to beef it up and so that there'd be a little more stretchroom near the wrist.

    Then I sewed it to rest of the sleeve assembly, top-stitched the bottom edge of the bicep section, and closed up the spandex base to finish off the sleeve. The little tab section I'm going to handsew next to the other side of the forearm guard just to hold it down. Now I'm off to finish that other sleeve before my energy runs out!

    1.jpg 2.jpg 3.jpg 4.jpg 5.jpg 6.jpg
     
  23. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Aaand the undershirt fits! Just gotta secure those forearm flaps down at some point and attach the Avengers shoulder logo and forearm magnet, which I'll do later since I'm waiting on my magnet pieces to come in and wanna do my casting work for some smaller pieces all at once.

    shirt.jpg
     
  24. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Sleeves look great - it's really coming along! :)
     
  25. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks man! Yeah I'm moving as quick as I can on this while still keeping the quality up. I've got a little under 3 months left, but no reference for how long this'll take me so it's maximum speed the whole way haha
     
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  26. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Just a quick update, haven't been able to work on the suit since wednesday since I was in Baltimore for Otakon until last night. This is the one thing I was able to complete before heading out, the headliner foam base for the torso overshirt. Decided to pattern it from the same patterns for the actual overshirt so that everything would lay the exact same way. Now, time to see if I can make up for 4 days of missed sewing!

    armor 1.jpg
     
  27. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Alright, think I managed to makeup for some list time in the past 2 nights! Made the fabric part of the lining and partially attached it to the headliner foam, turned it inside out when I put it on the mannequin to get an idea for how the actual armor will look. Then tonight I made the trims that go out from the chest star, and quickly attached the cordura panels at the top and bottom of the trim. Was about to attach the spandex center piece, but decided I should probably get some rest. Might topstitch a headliner foam outline of the star into the spandex to give the star something to be set into tomorrow as well.

    armor 2.jpg armor3.jpg armor4.jpg armor5.jpg
     
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  28. spartacus1

    spartacus1 Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    That's looking great! I just finished with my vest and I had a very difficult time with the star area, especially due to sewing the spandex to the more rigid fabrics. What kind of spandex are you using?
     
  29. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks! And yeah I just finished the star section myself and it was rough, thankfully topstitching smoothed out the corners! And I'm using a heavyweight or "jumbo" spandex for all the dark blue spandex sections.
     
  30. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Blasted through the rest of the chest/upper back sections last night and the night before. All that's left for the upper section of the armor is to connect the side seams, make the collar and install the zipper/zipper cover. Trying to decide if I wanna do the collar/zipper tonight so that the upper torso section is done, or if I wanna wait until I do the stomach/lower back sections and connect everything before putting the collar/zippers in.

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  31. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Looking awesome! Are you doing the keyhole in the back or is it all going to be solid?
     
  32. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Yep I'm doing the keyhole! I'm a little worried that I might not have made the cordura back panel on the undershirt wide enough, but if I did all my other measurements right than the spandex should remain hidden haha
     
  33. spartacus1

    spartacus1 Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    This is looking absolutely amazing! I can't believe you are a newbie. Your sewing skills are awesome. I'm working on my own now and I'm constantly comparing it to all these perfect builds!
     
  34. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks a lot! And well, I actually have been sewing for about a year and a half, but usually smaller and simpler things at a novice level. I more meant that I've never done a project this large and complicated and precise in its detailing, but that's what happens when you make thread titles on 4 hours of sleep :p I will say though, working on this suit is definitely pushing my skills and to new levels.

    Plus SMP Designs' writeup on his cap suit is a massive help to me, and sewing at grandma speeds with your face in front of the needle helps too haha
     
  35. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Last photodump for the upper torso before I move on to the stomach and back section!

    Honestly, I think the collar is the thing I'm most proud of so far. I am TERRIBLE at collars and have never gotten them to set into the neck properly, so I'm really happy that I set not one, but TWO collars in right where they need to be :) Also pretty happy that I managed to get that invisible zipper to run through both the collar and the back properly, although I covered it with a panel of cordura so not that it mattered TOO much how it looked.

    armor6.jpg armor7.jpg

    Also pretty happy that I managed to get that invisible zipper to run through both the collar and the back properly, although I covered it with a panel of cordura so not that it mattered TOO much how it looked. I topstitched it one side of back, and I'm gonna get either some velcro or some sew-in snaps to help secure the other side in place properly. I also attached the liner to the shell at the neck, the armholes, and the zipper-seam, leaving basically the key hole and bottom edges open to connect to the lower torso sections. And lastly, I epoxied the star into the center so that it's stuck on for good.

    armor8.jpg armor9.jpg armor10.jpg
     
  36. Straycatt

    Straycatt Well-Known Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    You are pulling off some great work here. You are motivating me to actually get back to work on my Winter Soldier Cap Motorcycle suit.
     
  37. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks a lot! And ooh definitely do that, the WS suit is tied with the AoU suit for my favorite so we definitely need more of those in the world!
     
  38. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Everything is lining up perfectly, very nice! Now you get to have fun sewing in the 8 billion little pieces of foam padding on the torso - woo hoo! ;)
     
  39. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Aaaaaayup! Haha, I actually started on the stomach sections and the liner tonight, including making my stencil for both marking where the foam pieces go AND for marking them in the foam for cutting. Aiming to start sewing in the foam tuesday, zipper foot don't fail me now :p
     
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  40. dog of ulthar

    dog of ulthar Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    *, this is looking amazing. The headliner foam padding was a really good idea.
     
  41. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Thanks man! Credit for that has to go to SMP Designs though :) Never would have thought to use it if it weren't for his write-up!
     
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  42. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Blasted through this section pretty quickly. I've got the shell for the stomach section done, although I may redo the topstitching on the top cordura piece since up close it's definitely not my best work. Also included some closeup shots of the topstitching on the ponte sections. Still have to attach the jumbo spandex back-side pieces and make the lower back section. I also made the cotton liner for the stomach section as well as the stencil that I'll use to mark/cut out the foam pieces, mark placements on the liner, and mark sewing lines on the shell. I'll need to cut all the pieces a bit smaller than I originally thought though since I forgot to account for the topstitching seams when I made the stencil and I don't want everything to overlap. Though that's as simple as marking the foam with a thick sharpie and cutting inside the line as opposed to outside.

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  43. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Oh the memories. Makes me want a drink just thinking about it. :)

    If you don't already have one, a compensating presser foot will make this part a lot easier. That, or a 1/4" zipper foot. The standard zipper cording foot is really too wide to get between all the little layers.
     
  44. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Ooh didn't think of that, you're right. Would something like these do the trick?

    http://www.amazon.com/Distinctive-A...F8&qid=1438712131&sr=1-4&keywords=zipper+foot

    http://www.amazon.com/gp/product/B00MPJ3DXA/ref=ox_sc_act_title_3?ie=UTF8&psc=1&smid=A353OFJ1T3F9U3
     
  45. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    That looks OK. I usually buy left and right facing feet as I personally don't like the adjustable ones. Be sure you're low shank. Do you have a domestic or industrial?
     
  46. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Domestic, it's a Singer Futura XL-400, so it mainly uses snap on feet but supposedly you can use screw-on low shank feet as well.
     
  47. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Ah, ok - I have a Singer 20U industrial. You might be ok with this one. Take the chance - if it works, it'll be a great foot and you'll be able to use it a lot.
     
  48. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Man I'm jealous, unfortunately I don't think I'd ever be able to justify the cost of an industrial as great as they are. And yeah since they're cheap I might get both and just toy around, see which serves me better. Thanks man!
     
  49. SMP Designs

    SMP Designs Sr Member RPF PREMIUM MEMBER

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    I had to. I worked for a time out of an industrial shop that I used to work for and the management after me gave me "friendly access" to the shop. Once they left, I had to outfit my own space. I got mine on Amazon for right at $1k in 2010. It paid for itself in less than 2 months.

    The real commitment is space - you can't move it around as it's on a table and weighs about as much as a VW.
     
  50. brutuswayne

    brutuswayne Active Member

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    Re: Age of Ultron Captain America Build (newbie's first Cap suit)

    Whoa that's awesome! Yeah space'd be an issue for me. Don't have a dedicated sewing room so I gotta be able to pack away my stuff for a weekend anytime the dining room is needed haha, the sufferings of a hobbyist.
     
    SMP Designs likes this.

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