Custom Made Darth Vader ROTS WIP

Discussion in 'Star Wars Costumes and Props' started by JUSTINIAN, May 21, 2012.

  1. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    I am working on making an accurate ROTS Darth Vader, completely from scratch. I started out with making a leather body suit from old clothes and some leather material.


    I started out with an old pair of pants that were very light weight (I was expecting it to get hot, so I wanted to cut back wherever I could)

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    After I took all of the extra stuff off (pockets, belt loops, buttons, etc.) I cut them apart into four sections and labeled them accordingly. Front left, back left, front right, and back right. Then I laid them out on the leather material and cut out the sections.
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    To get filled out effect I was looking for I put 2 layers of quilt batting (the cotton padding the goes inside blankets) between the old pants and the leather. I had to use 2 layers, because 1 wasn't enough to get it raised high enough.

    I took a yard stick and drew 1 inch lines on the pants, and quilted along them.
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    4 hours later I had all four sections quilted.
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    Then I sewed the sections together.
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    I added a zipper and button, to make it easy to take on and off.

    Here I am weraing the completed pants.
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    They are quite flexible, but pretty heavy duty and very hot.
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  2. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    I started out with an old T-shirt and cut long sleeves out of another old shirt.
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    All of the quilting done.
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    After sewing the top part of the torso together I made sure I could get my head through, and it fit well.
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    Here are the sleeves sewn on.
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    Here it is complete.
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    Here is the full body shot.
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  3. Eopie Herder

    Eopie Herder Sr Member

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    So you designed it as a slip on shirt instead of having a zipper? Interesting!
     
  4. camerafx24

    camerafx24 Active Member RPF PREMIUM MEMBER

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    look's great.
     
  5. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    I actually needed this for another costume, and didn't have time to put the zipper in. I would eventually like on though.

    I also was able to get a pretty good start on the shins. I made one out of pepakura, just to make sure my size was right.
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    I then did a layer of fiberglass on the inside to strengthen it.

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    Then I started my Bondo work.

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    I used a laser to cut out the detail for the shins, and then glued it into place.

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    After a lot of sanding I am pretty pleased with the way they turned out.

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    I still need to finish the detail on the indentations. I'm hoping to get back to work on them soon.
     
  6. poholio

    poholio Active Member

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    This is looking great! You are giving me some ideas for my own build. Thanks for posting this.
     
  7. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    I'm glad it was helpful. Yours gave me some ideas for some of the small bits.
     
  8. Rysjin7717

    Rysjin7717 Well-Known Member

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    lTh' dark lord of th' sith evil incarnante that commands with a iron fist I find your lack of faith disturbing!!!! nice shirt and pants good work on th' shins as well i'll be keeping my eye on this thead for sure brah.:cool:cool
     
  9. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    Well after a long time, I have finally returned to this project. :D

    I spent a ridiculous amount of time sanding and tweaking and filing on these stupid indents on the shins. But they are almost done.
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    I just have to do some small filler in a few spots and then they will be pretty much done.

    As always let me know what you think, or if anything needs adjustment.
     
  10. omel

    omel Well-Known Member

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    wow those shins turned out amazing...wish i had the same patience and talent when it comes to bondo and sanding...
     
  11. poholio

    poholio Active Member

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    Those shins are looking spectacular!
     
  12. BenCozine

    BenCozine Active Member RPF PREMIUM MEMBER

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    Really interesting work, love the shin guards.
     
  13. Rysjin7717

    Rysjin7717 Well-Known Member

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    Lovin' those shins brah, you've done some accurate work there.:cool
     
  14. AZJedi

    AZJedi Member

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    Wonderful work thus far!
     
  15. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    Thank you all for the comments.

    Ok. After some thought, I have decided to mold these. I did some fine tuning, and made one of the shins to be completely symmetrical, so it can be molded and then create castings for the left and right. I had to bring in the bottom ankle parts, because they flared out too much. I also did some more tweaking on the indents. And then it was ready for the spikes. Here is the final primer:
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    I hope to get the gloss black done on it within the next few days, and then I can start the molding process.

    Hope you enjoyed seeing this as much as I have.
     
  16. omel

    omel Well-Known Member

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    that is beautiful bro! BEAUTIFUL
     
  17. James Kenobi 1138

    James Kenobi 1138 Master Member RPF PREMIUM MEMBER

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    Those shins are ace, great work.
     
  18. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    Thanks, guys.

    I finally got the clear done.
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    I should be ready to mold it tomorrow.
     
  19. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    I got my clay in finally, and built it up for the mold.
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    Here is the print layer of silicone.
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    Hopefully later I can add a thicker layer.
    Enjoy.
     
  20. omel

    omel Well-Known Member

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    Daaang Bro! that is gorgeous! if only you were in my country i'd order a pair of those shins if you ever make a run!
     
  21. pinder91

    pinder91 Sr Member

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    Wow! Very inspiring, man. Can't wait to see what's next.
     
  22. Rysjin7717

    Rysjin7717 Well-Known Member

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    Justinian, that is some phenomenal work on those movie accurrate shins brah!!!!:cool:cool
     
  23. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    Thanks guys. I always appreciate your comments.

    After 5 layers of silicone, a layer of rondo, and then a layer of fiberglass, this mold is ready. I ran out of my regular resin, and luckily found another can on a shelf, that is why the fiberglass jacket is two colors.
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    Here are both parts all trimmed out.
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    And the final assembly.
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    I also got some more casting resin in, but that will have to wait until next week.

    Hope you enjoyed this.
     
  24. Rysjin7717

    Rysjin7717 Well-Known Member

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    All of th' details of th' original have been captured in th' mold great job brah.:cool:cool
     
  25. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    Thanks.

    I did my first set of pulls. I sprayed primer into the mold, and then put down 2 layers of fiberglass mat. There are a few imperfections, but overall I am very pleased.
    [​IMG]
     
  26. Turrican

    Turrican Active Member

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    If you should offer a set of those, count me in for one.
    They look realy close.
     
  27. Toxx

    Toxx Well-Known Member

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    Why don't you go with a black gel coat?
     
  28. Turrican

    Turrican Active Member

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    Maybe cause it's very toxic?
     
  29. JUSTINIAN

    JUSTINIAN Sr Member RPF PREMIUM MEMBER

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    Thank you. I will eventually get to casting up some. I just want to get this build completely done, before I try to do anything else with it.
    I didn't have any gel coat, and I knew that fiberglass works well enough. I have also heard that gel coat is pretty tricky to get right. In the future I may experiment with it, but for now this works fine.
     
  30. DynamicMenace

    DynamicMenace Active Member

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    wow man those tuned out amazing. very nice craftsmanship. looking forward to the rest of the build
     

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