Boromir, Full Costume Build (Pic Heavy)

Discussion in 'Replica Costumes' started by Anduril, May 5, 2012.

  1. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Over the past several months I've been researching and collecting bits and pieces for a dream costume of mine, Boromir from The Lord of the Rings.

    He's one of my favorite characters and has such an awesome outfit, one I've been wanting to make for years and I really want to do this well.

    The plan is to get this done by October where there are a couple of events I'd like to wear it too, not to mention the Hobbit premier at the end of the year.:)


    Anyway, onto the build!

    I've got most of the materials I'll be needing for the outfit already besides the leathers which I'll organise to get soon and I'll hopefully be getting myself a Stansborough Cloak when the funds are looking a little healthier too :p.

    I have some nice velvets, satins and faux leathers I've gathered up and also some fantastic looking bullion embroided trim and a Sari I ordered from India for the collar and tunic sleeve details:
    [​IMG]
    The embroided patterns aren't an exact match to the screen used costume but after looking at lots of these sorts of items over the past months these are pretty similar and will work until I find something better to upgrade with further down the track. ;)

    I was fortunate enough to score one of BlindSquirrel's Horn of Gondor kits which is such a nice piece to own and I can't wait to clean it up and give it a few coats of paint!
    I've also got some accurate buttons for the tunic and a heap of jump rings for the chainmail sleeves:
    [​IMG]


    Since Boromir's outfit its made up from a few different layers I've decided to start from the bottom layer and work out from there so everything fits properly at the end.
    So thanks to disk 3 from The Fellowship of the Ring Extended Edition DVD and the LotR Weapons and Warfare book I managed to get some nice pics of the bottom layer of the costume.

    Here's the part I'll be making first:
    [​IMG]

    Step 1:
    Chainmail!

    I've never made chainmail before so this was a new experience. After looking at a lot of tutorials online for 4 in 1 chainmail I began weaving all those Jump Rings together. So that's pretty much all I've been doing over the past 5 days when ever I have spare time and as of tonight I almost have one sheet done for one of the sleeves:
    [​IMG]

    I know all the chainmail done by Weta Workshop was originally plastic pipe cut up into rings and painted, which is what I originally wanted to do but after a lot of thought I decided to go with pre-cut aluminium jump rings.
    The deciding factor was that I don't actually have any tools suitable to cut up the rings and it would save a lot of time and effort to just buy metal ones.:unsure

    So that's where I'm at so far. I might take a break from weaving chainmail tomorrow and get out into the shed and start on the Horn of Gondor :D
     
  2. markkNL

    markkNL Member

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    The chainmail is looking good. When I was working on some chainmail (never finished what I wanted though), I bought steel wire and rolled it around a stick of approximately 1cm diameter, then took it off and cut rings of it. That might be a lot cheaper than just buying rings.
     
  3. pinder91

    pinder91 Sr Member

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    Very nice! I'm loving the chainmail. Any worry of the rings coming apart, or are they pretty snug?
     
  4. Thranduil

    Thranduil New Member

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    Your chainmail is looking great. I'm surprised you've chosen to make it yourself rather than just buy a shirt, but that may be both a financial as well as personal decision.

    I'm a huge LotR fan, so I'm looking forward to watching your progress on this costume.

    I like the picks you've made for your cloth, they're definitely close enough to original.
     
  5. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Thanks for the feedback :).

    The rings were only $9US per 1000 and shipping was good too so they aren't that expensive and was a nice easy shortcut :p.

    I've scrunched the chainmail around a bit (Not too vigorously though) and it's held together find. It requires pliers to open and close the rings so unless you yank on them really hard I don't see them coming apart easily.


    So I have started cleaning up my Horn of Gondor, sanded it and filled in any blemishes with some body filler:
    [​IMG]

    Then I primed it, sanded it back again and it's now drying out in the yard with another coat of primer on as I type so more pics to come soon :)
     
  6. Popeanator

    Popeanator Active Member

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    Awesome, what ideas do you have for his sword?
     
  7. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    I already have a United Cutlery Boromir Sword which will be great for photoshoots and to display with everything once its finished but I'll probably make a wooden version for when I wear it at public events like conventions and The Hobbit Premiers.
     
  8. jollyskeleton

    jollyskeleton Active Member

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    Looking good man! Excited to see the progress :)
     
  9. CelticRuins

    CelticRuins Sr Member

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    This is looking great!
     
  10. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    I've been working on the Horn some more over the last few days and it's nearly done.

    I just sprayed a white base coat over it, then some gold over the bands followed by some silver Rub'n'Buff for the silver details. I then did a brown wash over the gold and some black over the silver to age it a little.
    The white "bone" parts I then applied some thin watered down layers of off whites and browns followed by another white drybrush over the top to add some texture.

    So this is how it's looking so far:
    [​IMG]

    I just need to braid some leather for the strap, attach it and it's done! :)
     
  11. Eveningarwen

    Eveningarwen Well-Known Member

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    Ok well 1) this is turning out awesome already! I love seeing builds like this of more random characters!

    2) Where did you get that buillon trim?!?!?!?!?!?!??!? I desperately need loads of stuff like that!
     
  12. jollyskeleton

    jollyskeleton Active Member

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    That Horn of Gondor is beautiful!!
     
  13. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Thanks guys:)

    Eveningarwen, I found the trim on ebay after a few searches, here's the stuff here: Hand-Beaded Trim. Gold Bullion on Rose Velvet | eBay
    For the bullion emboided sari I just searched for "Vintage Sari" and found that awesome one I ended up with.

    Update time!
    The Horn of Gondor is now finished, after a few attempts at round braiding (after never braiding anything before) I finally started to get the hang of it and after a couple of hours I ended up with a strap for it.
    I attached it to the Horn and here it is pictured with my UC Boromir Sword:
    [​IMG]

    Big thanks to Blindsquirrel for making the Horn kit, I'm sure if I'd attempted my own scratch built one it wouldn't have turned out anywhere near as nice :)

    Now back into the chainmail, still need to make that other sleeve :S
     
  14. Rikarus

    Rikarus Well-Known Member

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    Last edited: May 14, 2012
  15. Sparticle

    Sparticle Well-Known Member

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  16. NelBearPig

    NelBearPig Member

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    very cool
     
  17. SailorEarth

    SailorEarth Active Member

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    Looking good! Are you going to go from a bought pattern or draft your own when you get to the sewn bits?
     
  18. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Thanks, I already have heaps of reference pics though, especially from the costume gallery on the DVDs which has some nice closeups of all the layers.

    Wow that's so much easier to understand than a lot of the other tutorials I looked at, though it's already done as you can see in my previous post. I might re-do it eventually so link bookmarked ;)

    I'll be doing a bit of both, modifying some patterns that I have for some pieces and making my own for other bits.


    I've finally finished the chainmail sleeves so I can start on some of the sewing stuff now:
    [​IMG]
    (The bottom sleeve looks bigger in this pic but it's mainly due to the top one being a bit more "scrunched up" and from the angle of the pic. Not that it really matters since the ends won't be seen anyway :p.)

    I've got some grey raw silk I'm going to quilt for the gambeson sleeves and embroid some silver stars onto then attach it to the leather shirt i'm yet to make. Hopefully I'll have some of it to show of by tomorrow night :)
     
  19. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Ok, so I've thrown together the beginnings of the undershirt:
    [​IMG]

    Before I can sew up the sides and finish this part I need to make the gambeson sleeves so I can sew them onto the shirt before attaching the chainmail.

    Here's a close up of the screen used costume piece I'm trying to replicate:
    [​IMG]

    It's not quilted in the usual way a gambeson is (not that I'm an expert), but it has the raised criss crossed detail through it so I've tried to mimic it with my machine on the fabric I'm using.
    I marked out all the lines with some tailors chalk then folded on each line then ironed along it, then I sewed right down the very edge of the fold. I then repeated it in the other direction:
    [​IMG]

    It's been a long process, especially for something you wont even be able to see once the costume is all on over the top of it but when I know something was there on the original costume I do my best to make mine look the same.:rolleyes

    So here's where I got to with it tonight:
    [​IMG]

    Nearly finished it, then I can cut out the sleeves and embroid the little silver stars into every few squares.
    I'm considering trying to dye it a darker grey first since this grey is a little lighter than the original...

    That's it for now, stay tuned for more soon! :)
     
  20. aeonpulse

    aeonpulse Sr Member RPF PREMIUM MEMBER

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    Wow, great work so far! I can only imagine how tedious putting together that chainmail must have been!
     
  21. Thumper1148

    Thumper1148 New Member

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    Wow, the attention to detail here is great!
     
  22. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    I'm getting close to finishing the undershirt now.
    I completed the sleeve pieces and sewed them on to the shirt, I then hemmed the ends so I could see where the embroided stars would go.

    I then used my sewing machine to embroid the stars on using the zigzag stitch with 0 stitch length and a couple of narrow stitch widths to get the right effect:
    [​IMG]

    And the finished embroidery before sewing the up the sleeves:
    [​IMG]

    So now I've sewn up the side seams and arm seams and punched holes where the leather loops will go to attach the chainmail.
    Here's the shirt so far with some of the maille over it to see how it will look:
    [​IMG]

    I just need to add eyelets and laces to the ends of the sleeves, add laces and a zipper to the front, hem up the bottom and of course attach those chainmail sleeves. :)
     
  23. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    ....And it's done!:
    [​IMG]

    Once I have all the other layers done you'll only see about 5% of this and it will probably be the piece I spend the msot time on with all the chainmail, embroidery and criss crossing seams...:p
     
  24. Gator Fett

    Gator Fett Well-Known Member RPF PREMIUM MEMBER

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    Incredible attention to detail. Looking forward to seeing the rest of the costume.
     
  25. Rysjin7717

    Rysjin7717 Well-Known Member

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    I'm liking this as well, attention to detail is just stunning brah keep up th' good job.:cool:cool
     
  26. jedimika

    jedimika Member

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    Very nice! Really liking this.
     
  27. BlindSquirrel

    BlindSquirrel Sr Member RPF PREMIUM MEMBER

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    Nice job on the Horn and an amazing build on the suit! I can't wait to see the rest of it!
     
  28. Banzai88

    Banzai88 Sr Member RPF PREMIUM MEMBER

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    Very inspiring WIP. You've got a great start--thanks for posting this!
     
  29. misswolverine

    misswolverine Member

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    This is incredible!!! You've definitely got all the details covered- I can't wait to see the costume continue to progress! :)
     
  30. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    I've been distracted recently finishing off another costume but now that it's out of the way it's full steam ahead on Boromir!

    I made the pants a couple of weeks ago (No pics though, they're just basic pants! :p), made with black velvet with a draw string, which is what they're described as in the Weapons and Warfare book, there's no photos that say otherwise so I went with that description.

    Since then I've been figuring how I'll do the silk under tunic.
    So far I've cut out the pieces for it and I've also been cutting up that really nice vintage sari I bought a few months back:
    [​IMG]

    Quite a bit of time spent so far cutting out all the little bits of gold wire embroidery:
    [​IMG]

    My plan is to tac down all the embroided pieces on the fabric I'm using in a way that closely resembles the embroidery on the original tunic sleeves.

    Tonight I layed out a few bits on my fabric to get an idea of how it would look:
    [​IMG]

    So hopefully this works out the way I hope it will and will keep you all updated as I get some more done. :)
     
  31. sweeper

    sweeper New Member

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    Wow, you have done a great job so far!
     
  32. Rikarus

    Rikarus Well-Known Member

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    wow, beautiful and inspiring!
     
  33. SupernaturalFan

    SupernaturalFan Well-Known Member

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    You are an absolute nutjob! Such meticlous attention to detail, you've really got a handle on this costume, far exceeds anything I've seen done LOTR wise. I always thought Boromir was a sick Cbomb, the way he went beast on the Urak-hai with 20 arrow in him. LOL >.<

    On another note, are you available to do some sewing work? I'm looking for someone who knows what they're doing to sew together my Amazing Spider-Man masks and I just so happen to be in Melourne also, so nice and local plus I can pay in Australian currency.
     
  34. TAZNITBR

    TAZNITBR Active Member

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    Beautiful work bra, really nice and accurate job.
     
  35. DestinedAnarky

    DestinedAnarky New Member

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    This is so awesome.I can't wait to see everything finished. Keep up the great work.
     
  36. Freaklord

    Freaklord Member

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    Amazing! The work that goes into it shows! Love the character, and this work of art shows justice.
     
  37. Eldritch Arts

    Eldritch Arts Active Member

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    Absolutely beautiful! Stunning! The attention to detail and extreme care with this costume shows your love for the character so well, I cannot wait to see more! This is so inspiring! Taking the time really does matter and make a huge difference, I will try to follow your lead with my own costume :]
     
  38. Freya Willia

    Freya Willia Well-Known Member

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    Just in case you do any future cutting of embroidery, check out Fiber Etch:
    FIBER ETCH

    It works much better on plant based fibers however, but a lot of fancy embroidery is done on rayon - and Fiber Etch burns through that pretty well. It eliminates a lot of painstaking cutting with scissors, but make sure the embroidery thread is NOT plant based, or it will eat that too.
     
  39. Guri

    Guri Sr Member

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    How did I miss this thread?? Loving it. As it's been said, your attention to detail is awe inspiring. I'll be watching closely now!
     
  40. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Thanks for all the positive comments everyone, it helps motivate me through the more "tedious" stages of this project :).

    Progress is more of the same, just sewing on more sleeve embroidery:wacko.
    I did throw together a quick mock-up of the under-tunic and it came out pretty good first go, just had to make a few modifications and it's looking heaps better.

    Also, I've got a Stansborough Elven Cloak ordered which is one of the very few pieces of this costume I'm not making myself and tonight I put my order in for a Noble Collection Elven Brooch to go with it :).


    I'd looked into this stuff while researching how to burn-out velvet to make the cloak Boromir wears for the first half of the movie and it never occurred to me to use it for that. I'll keep that in mind if I do something like this again, thanks Freya :)
     
  41. booksandcorsets

    booksandcorsets Well-Known Member

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    Love the attention to detail, and what a clever idea for the padded gambeson. I had a similar project and I ended up "painting" the lines on instead of sewing; this looks FAR more realistic!
     
  42. clancampbell

    clancampbell Sr Member

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    Absolutely fantastic!!!!!

    Rich
     
  43. tauriice

    tauriice Well-Known Member

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    This is amazing work. Can't wait to see the finished product.
     
  44. elvis8atari

    elvis8atari Guest

    The horn of Gondor looks awesome. Keep it up.
     
  45. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Ok, I finally have some more progress to show off!

    The sleeve detail is pretty much done after many, many, many, MANY hours of sewing the bits of wire on by hand into the right pattern so I can finally move on! :wacko
    [​IMG]
    I don't think my neck has ever been so sore after being hunched over for so long :S.
    I'm fairly happy with how it's turned out so far, though I just know I'm going to look for ways to improve on it in the future :p

    I also recieved my Stansborough cloak a couple of weeks ago and today my Noble Collection Elven Brooch arrived in the mail so of course I had to take a pic of that too :p:
    [​IMG]

    Now I can get on with sewing the rest of the inner tunic so look out for more pics soon! :)
     
  46. Guri

    Guri Sr Member

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    Fabulous work. Those sleeves are drool worthy!
     
  47. Beechy McFly

    Beechy McFly Sr Member

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    So can I have it when your finished?? :lol Looks amazing and the detail is beautiful.. Nice Costume you'll have..
     
  48. Mados

    Mados Well-Known Member RPF PREMIUM MEMBER

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    Amazing work. The more I sew, the more appreciation I have for this type of work. Like you said, it can be tedious. Looking forward to seeing this completed! You should change the name of your thread to "One does not simply create a Boromir costume."
     
  49. Anduril

    Anduril Active Member RPF PREMIUM MEMBER

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    Haha I was wondering how long it would be until something like that was said!


    So I've finally started assembling the under-tunic and it looks like this costume is actually getting somewhere now!:
    [​IMG]

    Note: The Buttons and whole front section is just pinned at the moment, still trying to work out perfect button placement, etc, so it looks a little uneven in parts.
     
  50. Rikarus

    Rikarus Well-Known Member

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    wowzwer!
     

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