Basic TRON: Legacy Style Costume Build

[jyhash]

Greetings Programs!

This is a Tron Style Costume build that I'm trying to create on a budget and with limited time before the Midnight Showing on the 16th/17th. In essence this is in NO WAY screen accurate, so if that's what you're looking for, I'll let you know that up front (it angers me too, but whatchagonnadoaboutit?).

Anyway, I'll start with what I have so far in terms of planning stages and what I've been making whilst waiting for other parts to arrive in the mail.

I've decided that I'm going to base the whole costume off of a Padded Motorcycle Vest I found on LeatherUp.com:

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I liked this vest because of it's hexlike mesh, the armor like padding (which means less work with my EVA foam) and that it'd be a bit stiffer than my first choice:

So with the first one as a base, I bought these materials:

• 8 6mm 9"x12" sheets of Craft Foam (AKA Foamies, EVA Foam)
• 4 2mm 12"x18" sheets of Craft Foam
• 1 set of 3 Strong Rare Earth magnets
• E-6000 Glue
• 1 medium bottle of ModgePodge Matte
• 2 Sponge Brushes
• An Exacto Knife
• 1 3" plumbing PVC endcap
• 1 spraycan of Black Mate PlastiDip

Then I bought these Accessories:

• 1 Starter Long Sleeve Compression shirt (think Under Armor, but at 1/4th of the cost)
• 4 3 Meter lengths of 2.3mm EL Wire with quick connect plugs
• 1 12v inverter for EL wire (strong enough to power up to 50' of EL Wire)
• 1 4-way splitter for EL quick connect plugs
• 1 TRON Legacy Sam Flynn IdentiDisc

I already had:

• 1 pair DKNY Boots (from my 2009 "Star Trek: The Abrams Abomination" Costume)
• 1 pair of Leather padded forearm armor with a slight techno-ish bent to it

I still need to get the following items:

• 1 pair nylon sport gloves or pool cue gloves
• 1 pair compression lycra long johns or men's jogging tights
• 1 30"x60" Sheet of Craft Foam

To begin, I wanted to build a hub for my IdentiDisc. I measured the inside ring and found it came to 4.25". Going to my local hardware store I found this PVC Endcap for large plumbing jobs which was great because the EXTERIOR diameter was 4":

All I needed to do was widen it a little bit and It'd work as a hub to be attached to the back of the vest. I added a ring of the 6MM Craft foam to the outside ring and clued it down with some E-6000. I used a Rubber band to hold the foam in place:

After the E-6000 dried, I removed the rubber band and whittled the foam down until the IdentiDisc fit easily over the hub, but snugly enough to keep it in place. I then painted a coat of the ModgePodge on with the sponge applicator brush. I did it a couple of times, waiting 15-20 minutes in between coats:

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Ideally I'll want to continue coating it until the pores in the foam are no longer visible, and then I'll spray it with the PlastiDip, and then give it another coat of Modge Podge (thanks to Twinight and his Tron Guard WIP project for that process and tip).

I also began work on creating the Shoulder armor. I drew a pattern of what the armor would look like laid out flat, and only drew one half so I could then scan it into Photoshop, mirror the drawing to make sure the pattern stencil would be as symmetrical as possible. I used a large picture of Sam Flynn for reference:

I also made a pattern for the Leg armor, but will wait on that until I get the Pants for the costume.

I cut out the pattern and affixed it to the EVA Foam sheets and began cutting out in layers to create the "built up" look of the armor pieces. I cut out the top pieces out of the thicker foam then layered them down on top of some thinner foam and then made a base layer of the thin foam so they'd all be on one piece. I cut them out using the X-acto knife which was very easy to accomplish (just make sure you're doing it on a cutting board as the will go though the foam and into whatever lies behind it...your nice expensive dining room table for example):

I'm initially using regular old Elmer's glue to bond the sheets together, but I'm not sure of how sting the hold will be, much less when I try to go mold it. If it begins falling apart, I'll try Hot glue. I don't want to use the E-6000 as when it starts to heat up, the fumes MAY BECOME TOXIC. So I wouldn't recommend it for you, either.

I'll continue posting to this thread giving folks more information on my build. Please feel free to drop any tips you may have, or questions you may want answered as I'm probably one of the few who read through he ENTIRE 55 page Tron Costume Thread and made bookmarks of helpful tips and procedures.

Anyway, Keep watching for updates!

~JYH
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[jyhash]

Re: Basic Tron Style Costume Build (WIP)

For those of you playing along at home, the Elmers DID NOT work very well in mounting the foam to one another and I fear that when I heat it up, it will come apart. So I need to borrow a friend's hot glue gun to remount all of the pieces.

 

[twinight]

Re: Basic Tron Style Costume Build (WIP)

I used construction paper as a pattern. Once I trimmed it down to how I like it. I traced it onto the foam. For symmetrical pieces, I fold the paper sheet in half and cut the paper to get it symmetrical. How is the disc held onto the hub? If it's a friction fit, it will be difficult to replace when it's behind your back.

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

I used construction paper as a pattern. Once I trimmed it down to how I like it. I traced it onto the foam. For symmetrical pieces, I fold the paper sheet in half and cut the paper to get it symmetrical. How is the disc held onto the hub? If it's a friction fit, it will be difficult to replace when it's behind your back.

It's snug, but there is enough pliability in the foam still to be able to pull it off without much resistance. I'm still thinking I may heat it up and make it a tapered fit. I did buy those magnets after all, it would be a shame not to use them.

I'm guessing I need to get some larger construction paper then and try to get the leg armor going. Or maybe i'll just free hand it and make a pattern from the free handed foam construction.

I saw another build on the RPF for a New Vegas Ranger Armor that uses Foam Sheets obtainable from Harbor Freight that I may go and get. Though if I go that route, I'm thinking more and more going and getting a heat gun we'll be in order. For now I'm just using my stove's heating element on high (you work with what you've got)...

 

[MorbidCharlie]

Re: Basic Tron Style Costume Build (WIP)

I saw another build on the RPF for a New Vegas Ranger Armor that uses Foam Sheets obtainable from Harbor Freight that I may go and get. Though if I go that route, I'm thinking more and more going and getting a heat gun we'll be in order. For now I'm just using my stove's heating element on high (you work with what you've got)...

I'm going this route as well. Supposedly, it's good foam to work with and it looks like a decent amount for $14.99. You can't order it online though.

A heat gun is one of the few items on my Christmas list, so, hopefully I was good enough this year for Santa to bring me one. :lol

Looking forward to see what you do... I'm completely new to this myself.

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

Continuing my build, I re-glued (using a hot glue gun) all the foam pieces after rinsing the Elmer's Glue off of them. Then, after making sure the glue was good and set, I heated up my stove and began rounding out the shoulder armor pieces. Using an old large poster tube, I heated up both sides and pressed it down on the tube while it cooled. After a few tries, I got the shape I wanted and let them cool fully before the next step.

From there, I got out my sponge brush and layered on some of the Modge Podge matte. I waited 15 minutes and layered it on again. Taking care (as per Twinight) to eliminate all perception of the pores in the foam. As for tonight, I'm calling it quits. I'll probably lay another few coats of Modge Podge Tomorrow morning before work, and then when I get home take them out and spray them with PlastiDip.

I also got my EL Wire and inverters today, and will be getting posterboard tomorrow along with a frosted shower curtain and begin cutting the torso lighting patterns and begin laying the wire.

As for my leg armor the jury is still out if I'm going to go get the Harbor Freight foam pads. My main qualm is that it'll be hard enough forming the leg armor with thin sheets, getting something as thick as the HF foam pads to look good would be a nightmare without the proper tools (I have neither a band saw nor a belt sander to shape them). So I think what I'll end up doing is getting the large roll of 2mm craft foam and make the leg parts out of that. What really will end up being a challenge is heating up such a large foam sheet. I may end up going over to Beehive (a local equipment rental shop) and seeing how much renting a heat gun from them would run (as I guarantee the wife will say no to buying one).

More tomorrow hopefully

 

[twinight]

Re: Basic Tron Style Costume Build (WIP)

Harbor freight has a heat gun for $12.99 and grab a 20% coupon from a magazine or newspaper. I think the thicker HF foam pads will be too bulky for a tron costume. It works for armor because it adds bulk.

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

Harbor freight has a heat gun for $12.99 and grab a 20% coupon from a magazine or newspaper. I think the thicker HF foam pads will be too bulky for a tron costume. It works for armor because it adds bulk.

Thanks for the tip on the Heat Gun, Steve. Great find! Im probably gonna stay away from the HF foam pads for this build, simply because I don't have the tools. I do need to go get the large Craft foam roll though, hopefully that'll work for the leg armor well enough. And with the Heatgun, molding it to the curves in my leg should be easier now.

:confusedQuestion for you though: did you glue a cloth backing to the underside of your armor pieces to make it more rigid? I'm just curious if I can avoid this step, especially if I'm gluing it to a lycra undersuit. I'm also guessing that if I'm gonna glue it down that I don't want to Modge Podge both sides of the armor, to keep the pores open on the back to bond with the glue better...

 

[twinight]

Re: Basic Tron Style Costume Build (WIP)

Cloth does not make it anymore rigid. The only places I used cloth are areas prone to repeated bending and possible tearing. I've seen the larger 3mm foam roll at michaels.

 

[Sakara]

Re: Basic Tron Style Costume Build (WIP)

curious, as im looking into making armour from foam...ive not heard of this stuff, but im seeing it called modge podge by you and mod podge by others..are there two different types?

 

[tcsmit29]

Re: Basic Tron Style Costume Build (WIP)

curious, as im looking into making armour from foam...ive not heard of this stuff, but im seeing it called modge podge by you and mod podge by others..are there two different types?

It's the same stuff and Mod Podge is the correct name.

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

curious, as im looking into making armour from foam...ive not heard of this stuff, but im seeing it called modge podge by you and mod podge by others..are there two different types?

Nope, same stuff. Just a typo on my part.

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

Continuing to soldier on...

So, I went to the craft store again and got my large roll of Craft foam, and JIMINY CHRISTMAS is there a lot of foam in that roll...

Now that I bought my tights, I was able to make myself a basic pattern out of some butcher paper and begin tracing it onto the foam:

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As you can see, I modded it a little bit once I had the basic shapes and sizes down, trying to draw it more in line with the armor that Sam Flynn wears.

I decided to take advantage of the gross amount of foam I still had left over on the roll and made 2 sets, mainly so I could layer them up and give the armor more bulk if need be (it is only 2-3mm in thickness, after all). The next step on this is to put some Mod Podge coats on it and then plastidip it. I'm just wondering if doubling up the layers is a good idea or if I should just build up certain sections. At the knee bend section (where the foam is the thinnest in width), I may just want to leave it one layer thick to prevent any tears and to facilitate movement. I may not even want to Mod Podge that section (any thoughts on that folks?)...

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Next, I was pleased to find out that my Vest arrived via FedEx today (a day ahead of schedule, 'round the holidays no less!), so I wanted to begin my patterns for laying my EL wire.

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I took a look at the pictures of Sam that I have, and tried to make a pattern that looked similar but fit the contours of the vest and didn't overlay the pre-installed armor padding. I did this by getting a general shape and then cutting smaller pieces that fit and then connecting it all together into one large form with packing tape. Once I had the desired shape, I flipped it over and traced it onto the remaining posterboard and then cut it out.

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On the back I did the same thing:

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Next I wanted to test out the length of the EL wire I had coupled with a similar process to the one that Eddie described over on the other Tron Costuming thread. Laying the EL wire close to edges of the posterboard, I anchored it with the Packing tape I used earlier. Luckily it was the exact length I needed for the back piece.

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I'm sure it's a bit hard to see in the pic, but I laid that all by hand. I officially hate both EL wire and packing tape now.

I also traced the outline, with a bit extra on the edges, on my frosted shower curtain that I'll be putting over this to diffuse the lighting a bit. I don't have a picture of it right now, and I'm not going to go take one because it's 2:30AM, and I have work in 7 hours.:wacko

I'm probably gonna take tomorrow off of this because I have a friend I need to see, but I might get some stuff done before I hang with him so check back if not already subscribed. I hope by the end of the week to have the lighting rigs finished so I can begin Plastidipping the foam parts this weekend. And if all goes according to plan, the whole thing should be done by wednesday to see the movie on Thursday!

 

[TheIrishTwit]

Re: Basic Tron Style Costume Build (WIP)

few things. first: a bit off topic but, are you planing on going to the lanecaster mall theater (they have comfy chairs)? second: i absolutely cant wait to see this when it's all finished! and lastly how much did everything cost and where did you find it?

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

few things. first: a bit off topic but, are you planing on going to the lanecaster mall theater (they have comfy chairs)? second: i absolutely cant wait to see this when it's all finished! and lastly how much did everything cost and where did you find it?

Hi Irish,

1. Unfortunately, No I won't be attending any showings in Salem. It's an hour away, and I don't know anyone except my in-laws who live up there. I'm hitting two showings with my wife and friends at Valley River Center in Eugene, though: the 16th at Midnight, and Saturday the 18th at around 7ish or 8ish. If you were wanting to make the hour drive down for the showing, you could see the costume in person on either of those days, otherwise you'll just have to settle for pics.
:unsure~Sorry!

2. Me too!

3. All in all it looks like it's cost me (so far) : $212, all said and done. Mind you that was because I had to purchase virtually all my materials, as I didn't have any of this sitting around the house. The foam, the Undersuit, the Vest, all were bought specifically for this project. And new, I might add. Though Eugene may be lousy with thrift shops, they cater more to hipsters than costumers. I couldn't find any Compression shirts, baselayer tights, hockey or lacrosse armor, or motorcycle safety clothing ANYWHERE around here.

Luckily for you, since Portland is only an hour away from you, it may be worth taking a day and going around the Hawthorne district's shops and seeing if you can find pieces for a costume, if you are interested in doing one yourself. Though I would start soon if that's what you want to do. I started planning and building this right before Thanksgiving, and I'm not even done laying all the lighting yet. I think I will get it finished come Wednesday evening, and that's only if I work almost every night from 9PM to 2AM on it. Just so you have an appropriate measure of how much time this thing sucks up.

Just a word of advice:
- Make sure and plan out EVERYTHING before hand, with a deadline like this you can't afford to make mistakes (at least in my opinion, when there's money involved).

and

-Read this and this all the way through. I know it's a lot of reading, but it helped me plan immensely, and the folks in the thread are fantastically helpful.

Thanks for reading and stay tuned!

 

[TheIrishTwit]

Re: Basic Tron Style Costume Build (WIP)

wow that way more extensive than i even realized. i was just thinking the vest part with some EL wire on the boots/shin guards and forearm bracers with the ID disk on the back of the vest (of course). just a less extensive/time consuming version that is fitted to my style better. thank you for all the help and useful tips, i will definitely look into them in more detail soon.

Irish.

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

Hi guys,

Been busy the past few days (Friend Visiting, Spending time with the wife, Holiday Office Party), but it was not without work on the suit!

I was able to get all of the EL Wire mounted on the Posterboard. It was painful. Just in how repetitive and mind drudgingly boring it was. But it got itself done, Thankfully.

I was then able to begin wrapping the shower curtain diffuser around the Posterboard, which also was no picnic. Essentially, I cut out about a half inch border around the size of the posterboard pieces to enable a good fold-over. Then, as you are taping it down, you need to make sure and cut slits for the corners and rounded edges. Particularly fun on the Circle portions...

I found that the EL wires are deceptively long, too. I have enough to thread through the upper portions of my leg armor if I want, which is pretty cool as (per what you'll read later about the EL diffusion) I may need anchor my remaining EL Wire strand to the vest and other places.

I also was able to do some work on the IdentiDisc Mount. I took a piece of 6mm craft foam, cut it out in a circle roughly twice the size of the mount cylinder itself, then cut triangles into the foam to bend outwards.

I mounted the triangles around the (thankfully) hollow inside of the hub with glue, and eventually finished it off with black Gorilla tape for some added stickiness.

I then hot clued around the outside base of the hub cylinder thus ging a double sided grip.

I was also able to start Plastidipping today, as well as forming and Mod Podging the leg armor. I like how the leg armor turned out, and am almost considering not plastidipping it, but I don't like the clear/white edges that have how glue sticking out of them, so I think I'll do it just for that.

I also decided I needed two other armor pieces: A High Collar/neckguard...and (as much as it pains me to say it) a...Codpiece.

(This will be the last time we show exclusively or talk about this part of the costume)​

Look, in an ideal world, I'd have perfect pants that were tailored for me out of the proper materials, making sure to show as little as possible in that area. But the truth of the matter is that I'm a middle class person with a Theatre Degree and neither time nor money are on my side at the moment. You work with what you have.

Anyway, junk coverings aside, I plastidipped the shoulder armor and was quite pleased with the results; looks very good.

What I am NOT pleased with though, is how the lighting it turning out. I began to lay my black gorilla tape along the edges, taking special care to cover up as little of the EL wire as possible, and the light in a moderately lit room, is virtually INVISIBLE. This is with 2.3mm wire, and a 12v inverter driving one...ONE... piece of 3 meter wire. :angry

I'm afraid the rest of the glow will be more of the same. This will be great at a lowlight party, but for going to see a midnight showing in an amply lit movie theatre lobby? I'll be lucky if people even know that the light panels even have EL in them...

Not pleased, but I guess that means if I want a good costume, I'll have to invest in EL Tape and Sheets. it just makes me ticked as it's the only thing to go wrong with this suit, but it seems like it's a rather MAJOR detriment...:angry

As for tomorrow, I will be plastidipping the leg armor, IdentiDisc Hub, and Codpiece; taping off all the EL Panels; and using the fabric dye pen and making all the yellow on the vest black. I'll also probably be adding some Gorilla tape accents to the vest to make it look more rubbery. That tape is frakkin' amazing folks, I highly recommend it (though the glue is strong, so a bit of a bear to work with, but worth it).

I surmise by Monday everything will be ready to mount to the various locations on the suit, so therefore is the moment of truth. I'm hoping I can find contact cement to use for the anchoring. I have a tube of E-6000, but I'm dubious if that would be a good choice for the task. Also, as Steve said, Wax paper will also be needed. Which should be interesting to work with considering the Under Armor Style compression shirt is SKIN TIGHT. I'm guessing using he same stuff for the armor will work for the El Panels. Then again, that is only a guess. I hope it works, as the lat thing I need at the premiere is for things to start falling OFF.

So far, it has gone pretty well, and I'm putting a lot into this costume. I hope it ends up wowing folks come Thursday night...

As always, ask questions if need be, and I'll be better about posting more as we get closer to the premiere date.

 

[MorbidCharlie]

Re: Basic Tron Style Costume Build (WIP)

I'll ask you since you've been working with it... how flexible are the pieces that have been plasti-dipped? I know that your armor pieces really aren't desgined to flex, but are you able to bend them at all?

 

[SlimeNuttz]

Re: Basic Tron Style Costume Build (WIP)

badass man i remember seeing one guy at dragon con a few years back with the old white tron suit he has this thick el wiring on it that would glow like no tomarrow but idk what kind he used keep up the great work

 

[jyhash]

Re: Basic Tron Style Costume Build (WIP)

I'll ask you since you've been working with it... how flexible are the pieces that have been plasti-dipped? I know that your armor pieces really aren't desgined to flex, but are you able to bend them at all?

Charlie,

They are surprisingly VERY flexible. The Mod Podge coat doesn't really turn them fully, to coin a phrase, "plasticky". Just gives it a lamination layer than let's the foam hold a stiffer curve, but is still eminently bendy. For example, the leg armor looks and lays like leather armor pieces, but still bends as if it is a pice of foam and the plastidip +mod podge coat makes it look very leather like in it's sheen.