Cougashika
New Member
My first dive into the world of cosplay was building an exopack similar to those worn in James Cameron's Avatar. I am a part-time teacher, so I work on a budget. Fortunately several items were available for practically nothing.
I started with a standard full-face respirator mask. I used a North model 7700 because you can remove the acrylic face shield by just removing the plastic retaining frame. The face shield then became the template for the next step.
Next I purchased a replacement shield for a regular face visor at a local hardware store. Using the removed respirator shield I cut a shape from the replacement that would fit in the flange on the mask. I thought of using a heat fan to cause the shield to bulge outward, but decided to use the flat shield instead.
Next I drilled vent holes along the top of the shield, since the seal around the mask was air tight. at the bottom I drilled two additional holes, originally for verisimilitude (the original exopack mask had black fixtures at the same location).
From the hardware store I purchased a PVC fitting, 4 inches long by 1/2 inch diameter, with caps at both ends. I drilled four holes in the fitting; two roughly the same width apart as the holes at the base of the modified face shield, an two smaller holes roughly 90 degrees off, to mount the fitting on the mask itself. One cap had a cover, while the other end was left open.
The hose was from a CPAP ventilator I was given by my doctor. The original hose was clear plastic, but I wrapped the hose with olive drab duct tape (or "100 mph tape" for you military types). I modified fittings for a nebulizer that I bought from a local medical supply store, and attached the hose to the open end of the PVC fitting.
I poked holes in the rubber mask where I would mount the fitting using a soldering iron (NOT a gun!). For the holes aligned with the shield I cut some length of flexible oxygen tubing, also in the nebulizer kit, about 2 inches. I painted the fitting, tubing and hose end with black vinyl paint, then attached the fitting to the mask with wood screws and washers. The tubing was inserted into the holes in the shield, then the shield was sealed into the flange with silicone adhesive (the retaining frame would not fit using the flat shield).
Though the holes in the shield did allow me to breathe, the shield had a tendency to fog up, not to mention the build-up of carbon dioxide from my breath. I found a solution to both problems by hooking the opposite end of the hose to a portable inflator for air mattresses. The switch for the inflator is wired to the fitting on the mask. The inflator is hidden from view in a surplus army machinegun ammunition pouch (again, a SAW ammo pouch for you GIs). As a final touch I treated the inside of the shield with a non-fogging agent similar to that used in diver's masks.
Total estimated cost of exopack: $200; the most expensive part is, of course, the mask itself, which runs for roughly $130 from a HAZMAT supply house.
For the SecOps uniform I purchased some BDUs in the US Army's ACU pattern (not the actual uniform; the mandarin collar on the shirt looks wrong). I bleached the uniform, then dyed it in lime green cloth dye. Not perfect, but close enough for government work. Black leather military boots.
A significant departure from the movie is the load bearing vest. I had a choice of paying an obscene amount for a used surplus military vest, or a paintball special for $40. I went for cheap.
The result is not perfect; The camouflage pattern alone was impossible to duplicate. But for cosplay purposes it pretty close.
Next project: converting a Nerf gun into Matanza Arms CARB rifle!
I started with a standard full-face respirator mask. I used a North model 7700 because you can remove the acrylic face shield by just removing the plastic retaining frame. The face shield then became the template for the next step.
Next I purchased a replacement shield for a regular face visor at a local hardware store. Using the removed respirator shield I cut a shape from the replacement that would fit in the flange on the mask. I thought of using a heat fan to cause the shield to bulge outward, but decided to use the flat shield instead.
Next I drilled vent holes along the top of the shield, since the seal around the mask was air tight. at the bottom I drilled two additional holes, originally for verisimilitude (the original exopack mask had black fixtures at the same location).
From the hardware store I purchased a PVC fitting, 4 inches long by 1/2 inch diameter, with caps at both ends. I drilled four holes in the fitting; two roughly the same width apart as the holes at the base of the modified face shield, an two smaller holes roughly 90 degrees off, to mount the fitting on the mask itself. One cap had a cover, while the other end was left open.
The hose was from a CPAP ventilator I was given by my doctor. The original hose was clear plastic, but I wrapped the hose with olive drab duct tape (or "100 mph tape" for you military types). I modified fittings for a nebulizer that I bought from a local medical supply store, and attached the hose to the open end of the PVC fitting.
I poked holes in the rubber mask where I would mount the fitting using a soldering iron (NOT a gun!). For the holes aligned with the shield I cut some length of flexible oxygen tubing, also in the nebulizer kit, about 2 inches. I painted the fitting, tubing and hose end with black vinyl paint, then attached the fitting to the mask with wood screws and washers. The tubing was inserted into the holes in the shield, then the shield was sealed into the flange with silicone adhesive (the retaining frame would not fit using the flat shield).
Though the holes in the shield did allow me to breathe, the shield had a tendency to fog up, not to mention the build-up of carbon dioxide from my breath. I found a solution to both problems by hooking the opposite end of the hose to a portable inflator for air mattresses. The switch for the inflator is wired to the fitting on the mask. The inflator is hidden from view in a surplus army machinegun ammunition pouch (again, a SAW ammo pouch for you GIs). As a final touch I treated the inside of the shield with a non-fogging agent similar to that used in diver's masks.
Total estimated cost of exopack: $200; the most expensive part is, of course, the mask itself, which runs for roughly $130 from a HAZMAT supply house.
For the SecOps uniform I purchased some BDUs in the US Army's ACU pattern (not the actual uniform; the mandarin collar on the shirt looks wrong). I bleached the uniform, then dyed it in lime green cloth dye. Not perfect, but close enough for government work. Black leather military boots.
A significant departure from the movie is the load bearing vest. I had a choice of paying an obscene amount for a used surplus military vest, or a paintball special for $40. I went for cheap.
The result is not perfect; The camouflage pattern alone was impossible to duplicate. But for cosplay purposes it pretty close.
Next project: converting a Nerf gun into Matanza Arms CARB rifle!
