Blizcon 2019 WINNER Large Fabrication Category! World of Warcraft 8ft Fel Reaver

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indiefilmgeek

Sr Member
Getting the giant Fel Reaver 'boots' on and off with the stilts is just too difficult. So, I've decided to SLICE them open in the back and then open them up like a clam to get them around the stilted legs of my 18yr old. I'll snap the back of the legs closed once the leg is clipped to the stilts with rare-earth magnets.

Here's a walk-through of that decision:

So, while I ordered the rare-earth magnets I'll need for that part, I worked more on the 'toe' of the Fel Reaver. Specifically, the piece that I need to be hinged so it allows the user to naturally walk without crunching the toe of the boot.

Here is my hinge plan:
**I know I said 'neon' rather than 'nylon'... I just didn't care enough to re-record it. lol

And here is what it looks like with the plastic re-enforcement glued into place and the final pieces in place:

Submissions for the 2019 Blizzcon Costume Content is coming up at the beginning of August, so I want to have at least the legs done when we submit. That leaves the Torso/chest in August, The hands/arms in Sept, and finishing stuff up in Oct. :)

Keep building!
 

indiefilmgeek

Sr Member
So cool ! Fingers crossed you will make the deadline !
Oh, we will be fine on the submission. Blizzcon has some cool (and unique) rules. There are multiple 'check-one's that entrants must submit between now and the event in Nov.1

So, this first submission 'check in' at the beginning of August simply requires cosplayers to have a plan and material lists ready (what they call '10% done').

We are ahead of 10% complete, as I plan on the legs being entirely done by then. :)

Thanks!
 

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indiefilmgeek

Sr Member
Here is a look the way I'm using rare-earth magnets to easily open and close the back of the Fel Reaver costume legs.


And here is how that looks on the first leg I finished.

 

indiefilmgeek

Sr Member
Lots of updates to make, but I'm so busy building I haven't had time to update things. Let's start with the legs!

Using the rough shapes of the pep file, I built 8 of these smoke stacks for the legs.
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To give you an idea of all the cutting and gluing, here is a look at HALF of the pieces for the end caps of these (after I cut them all, but before I glued them together).
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Once I built the stacks, I attached them.
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Here is a look at the first two full-attached leg smoke stacks!
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I even tried them!
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Then I attached more detail pieces (the largest of which was a pool noodle! I used silicone caulk to create some shapes I wanted for this (to match the game model's texture).
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Then I sealed it with Plasti-dip primer.
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And then, hit it with a dark bronze base coat of paint.
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Lastly, I wired up LED lights for the Knee area and smoke stacks.
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Here is a video the light test...
 

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indiefilmgeek

Sr Member
********************
Chest Construction
********************

So, I'm almost done with the chest construction. I started with a pepakura file that I unfolded and modified from the game 3D model.
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After checking the scale to make sure it worked, I cut up the pep into foam templates.
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Which I then used to build the foam version.
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I then built the bars in the front of the chest plate.
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And then set up the 12v LED's I'm using for the lights on this unit.

...and, finally, since I want to be able to turn these on/off from outside the suit, I wired in a 12v remote control unit. :)
 

indiefilmgeek

Sr Member
I've also gotten a lot done on the Torso.

First the paper pep...
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This got heavily modified to fit a human in side of it...
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And then I used this paper model to make foam templates.
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From the front it looks like lapels. :)
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Then I started to work on the Shoulder Wheels. For reference here is the character again.
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And here is a close up of the shoulder wheel.
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I started by making the general shape.
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\

I then cut concentric sections out of this foam and push the inner section in slightly so this surface looks more like the texture of the game model.
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Then I added details.
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And then assembled the parts to make the shoulder wheels. This included a deeply inset side (on the outer side of the wheel from the body of the costume. This will allow our arms to pass through the wheel from the torso area and connect with the forearm/hand section.
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Next up is cutting a big hole in each of these where our arm will pass through... and then mounting these bad boys!
 

indiefilmgeek

Sr Member
After building out the those wheels, I created the shoulder units with smoke stacks.

Here is the game reference:
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I took 3D game model and made a pepakura paper version at full-scale.
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I then markup how I'll turn this into foam templates, including new edge ID's and cut angles. In this case, I also need to do a Right and Left version.
Here is the final paper templates with all the cut, fold and edge ID's that I then transferred to my EVA foam and then cut out on my band saw.
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After cutting all the pieces out, I usually re-assemble the paper model again as a guide to how the parts go together.
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Because the 3D game model only provide the rough shape of this piece, I had to modify it to match the look of the texture details used in-game.

Here are a couple shots of what the final foam build looks like.
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I also finished up the Cod Piece and spikes that hang off the belt of the Fel Reaver. These were done a couple weeks ago, but I haven't posted pictures of them yet.

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collinlueb

New Member
thanks for showing how you converted from a paper to foam file that helps a lot! do you just use a normal protractor to check the angles?
 

indiefilmgeek

Sr Member
thanks for showing how you converted from a paper to foam file that helps a lot! do you just use a normal protractor to check the angles?
Sorry for the delay... lots of building going on! lol

I actually really like Angle Finders for determining the angle of the cut I need to make. This one is $5 at Harbor Freight. Just remember that if the angle you want to achieve is 30 degrees against a flat surface you can set the cut angle to 30 degrees, but if you plan to cut both sides of your foam and join them together you'll need to cut both sides of the foam on 15 degree angles each so the TOTAL is 30 degrees.

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indiefilmgeek

Sr Member
HANDS!!!!

I'm really far behind on posting here, as I've been SUPER busy building for Blizzcon. Sorry about that! :(

I started with the game reference and them build them to scale in Pepakura.
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I then took the pep files and turned them into scale templates for my foam. I also decided at the last minute to add some articulation to them. Here's a look at the way I planned to run hi-tension fishing-line through the finger joints so we could open and close the hand. I used coffee stirs/straws to create a decent path for the fishing line through the foam.

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It's a big ole hand! :)
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Here's a video of how the articulation is working:

And here are both hands built.
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I then built the forearms for these massive hands to go into. This is what they look like in their base colors.
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