Cyborg Ninja (Metal Gear Solid) - pics of completed costume

Discussion in 'Replica Costumes' started by pandamajik, Nov 6, 2011.

  1. pandamajik

    pandamajik Member

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    A quick intro about me - I started off making some Gundam model kits and one figure resin kit and eventually found myself going to anime conventions about 3 years ago. I made a sword for my Strider Hiryu costume 2 years ago and that's pretty much the only prop I've ever made. I sewed a Roy Mustang costume last year and so I've decided my next costume is going to be ambitious. As a result, this is my first time for a lot of things (i.e. Pepakura, resin, fiberglass, and pretty much everything else here).

    I'll preface this by saying that I have only played Metal Gear Solid and none of the sequels. However, I loved the character design for Cyborg Ninja and I decided to make this my next cosplay project. I'm starting with the iconic helmet.

    [​IMG]

    I found a version of the helmet that someone had made and unfolded in Pepakura. I printed it out and proceeded to make it out of cardstock. The only thing is that it was designed too narrow so it would end up being too tall if the width was made to fit me.

    I decided I'd give 3D modeling a shot and started creating the helmet in Blender. I made the helmet in one piece for 2 reasons - I wasn't confident in modeling multiple pieces that need to fit together and it would be easier to model just a single piece. The plan is to make the helmet and then cut it apart later.


    I got a bunch of reference images and took some pictures of my head with the helmet superimposed so I could use it as reference when making the 3D model. I don't really have a background with 3D modeling so I had to read a lot of tutorials first.

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    Next, the finished model is exported to Pepakura and unfolded. This is then printed out onto 110 lb. cardstock and then cut out.

    [size=+2]Some people have been asking for the Pep file so here's a link.[/size] A word of caution - this is my first real attempt at 3D modeling and Pepakura and I did all the work myself so it's hardly as good as some of the other work out there. You may find some areas will need more filling. It's also a good idea to add some supports in when doing the resin and fiberglassing.

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    The pieces are scribed with a ruler along all the lines that need to be folded so the folds are really crisp. The pieces are then glued using regular Elmer's white glue. A thin layer is optimal so you don't have to hold it for minutes waiting for it to dry.

    The way the helmet is designed I can't put it on to check the fit so I was only able to check for an approximate fit when half of the helmet was glued. There helmet narrows in size around the mouth area so it can't just slip on.

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    I actually made three different Pepakura models. The first one was using a Pepakura model someone made and unfolded but after making the forehead piece I didn't really like the shape so I decided to make my own from the beginning stage of making a model. The second one was a bit small so I rescaled and the final one came out the right size.

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    Here's the profile of the Pepakura model.

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    The supplies I'm using for resin and fiberglassing. The chip brushes were from Harbor Freight. Be sure to wear a respirator when using resin and fiberglass. A simple dust mask doesn't stop the organic fumes.

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    The entire outside of the helmet is coated with a layer of resin and then the inside gets some resin and about 2 layers of fiberglass cloth. Make sure to tap the resin into the fiberglass and not just simply brush it on. 2StoryProps has a nice tutorial on the process complete with videos. Also, resin can eat through certain plastics including that blue cup you see there. I know some people use plastic cups so I guess these were just cheaper plastic. I had some Yogurt containers and that worked fine.

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    When the fiberglass and resin dries the helmet becomes very stiff but still remains very light.

    Body filler is then put all over the helmet and the cycle of body filler and sanding begins. Spreading the body filler in thin layers helps to minimize the amount of air bubbles.

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    I started off using Bondo brand body filler but it's not the best to work with in terms of spreading and sanding. I heard about Evercoat Z-Grip from a friend a while back and decided to give it a try. It's specifically made for automotive use so you can only find it at certain stores. I got mine at Carquest.

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    Here's some body filler being mixed up. It has a slight greenish tint. I also picked up a spreader which is made of flexible rubber so you can pop off the hardened body filler when you're done.

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    After a few rounds of body filler I sprayed a coat of gray primer to make it easier to see what needs work. The gray primer I'm using is Rust-Oleum Automotive self etching primer since I had some left over from working with resin model kits.

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    I decided to pick up a contour gauge so I could make the helmet more symmetrical. I also played around and drew on what the final helmet would look like.

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    Some areas are patched and then sanded again. Here you can see the various layers of body filler and primer. Light gray is Bondo, dark gray is primer and the light green is Evercoat Z-Grip.

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    Another coat of gray primer to check for defects. Then it's time for the spot putty for small defects. It was a lot cheaper to get the super huge size of spot putty.

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    A coat of brown primer. Here I'm using Krylon brand since it's cheaper.

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    If you look closely you can see that I filled in the right cheek (left side of screen) a bit more to match the left.

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    I made a paper template to get the shape I need to cut out. I think I made at least 10 different versions. You can also see the string that I'm using to mark straight lines for reference on the helmet.

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    I tried using a Dremel to make the lines but it was difficult to get a really straight line which is evidenced by the horizontal and vertical lines. The pentagon was first drawn on paper using this method and then traced it on to the helmet. I used two layers of masking tape for a bit of added thickness and then scribed it using a scriber then went over it with a small needle file.

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    The pieces were cut apart using a Dremel. It was actually cut apart before the last picture but I forgot to take a picture of the pieces until after. The problem of using the Dremel is that the cutting tool isn't the thickness of a piece of paper so you end up with approximately a 2mm gap in between all pieces.

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    I'm currently working on filling in all the gaps between pieces so it comes together cleanly. I tried the helmet after it was cut apart and it does indeed fit me. It's snug around the ears but it's not too bad. The reason for this is that there's about 0.5cm extra thickness due to the body filler to get the outside smooth. I probably don't need it this thick if I cast it. My initial plan was to cast this if there's some interest so if that happens there will be more room around the ears.

    I do have plans for making the entire costume but I figured I'd handle the helmet first before going on.
     
    Last edited: Jan 29, 2012
  2. ralphee

    ralphee Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Awesome, i do love this character, very cool headgear!

    lee
     
  3. ugameenough

    ugameenough Active Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Dude awesome! Im a real MGS head. lol iIwould love to build one. Care to hook a brotha up? lol I havent started by pep builds because I dont have windows. Yea i know sucks to be me but hey thats what these forums are for right? A lil help here... A lil help there and you got yourself a build. lol Well cant wait to see ow this comes along. Looks like your gonna breeze through it. PM me if ya care to work something out.
     
  4. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Haha I don't think I'm going to be "breezing" through this since I'm learning as I go. I can PM you my Pep file and even my original 3D file but I do have to caution that there's probably a few areas that could have used some refining. If I could do it again I would definitely have built it with more polys since the pep is less time consuming than putty work. I also built it without struts so part of the very back warped in a bit causing me a headache when matching the symmetry. Let me know what you need and I'll PM you.

    In terms of scaling I had pictures of my head both in profile and front view with a ruler held underneath so I could measure the dimensions accurately. Add a bit for wiggle room and that's how I did the scaling.
     
  5. Ruddigger

    Ruddigger Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Great idea for a build, I'd love to have one to display with my signed copy of Metal Gear Solid.
     
  6. jnjoker100

    jnjoker100 Active Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I would love to get a copy of the pep file. I think the kamen rider helmet could be modded into it.

    Great build btw looking forward to more updates.
     
  7. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    PM me and I'll give you a link to the file but I have to caution that it's not nearly as polished as many of the other files around here because I did all the work myself (3D model, unfolding, etc) and seeing as how I have no expertise in either field it's fairly amateur work. I didn't build in supports so make sure to have some when you make it or else you'll probably get some warping. Aside from that if anyone wants the base model to improve upon I would be more than happy to provide that in any file format since I'm pretty sure I can export as various file form from Blender.
     
  8. BlackKaos

    BlackKaos Well-Known Member RPF PREMIUM MEMBER

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    Re: Cyborg Ninja (Metal Gear Solid)

    Awesome build. Love the way the helmet is looking so far.
     
  9. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Thanks. I've been having some trouble with filling in all the gaps where I cut stuff apart so that the pieces will fit back together nicely. Just about to head to Harbor Freight to pick up a few things so I should have some more progress tonight.
     
  10. ugameenough

    ugameenough Active Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    thanks for the file. ive cut and scored it last night. now time to hot glue it together. and ould you believe i never knew what a contour gauge was till this thread? lol n e how thanks again ill keep u posted....
     
  11. Dark Knight86

    Dark Knight86 New Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Thats fantastic great work
     
  12. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I actually learned about the contour gauge from a picture Volpin had during a Daft Punk helmet build. I got a cheap one from Harbor Freight for less than $5. You have to be careful using it since it doesn't "lock" in place so you have to watch for it shifting on you when placing it over the other side.

    After I cut everything apart I started to work on cleaning up the edges and filling in the gap that resulted from using the Dremel to cut it apart.


    I taped everything together to check for what areas needed more work.

    [​IMG]


    You can see here that there's a gap in the fit of some pieces in the horizontal direction, namely the bottom pieces. This is because they're under stress but because it was one piece before it wasn't evident. When it gets cut apart they naturally flex in a bit to relieve the stress. I can just skim some body filler on those areas later.


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    The way that I'm fixing edges is by using the "bondo squish" method. I'm using aluminum foil there because body filler doesn't stick to foil very easily. I cover the edges in some body filler and just lay it down on a flat surface. When the body filler dries I have a nice flat surface and both sides are also parallel with each other.

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    For the gap where two pieces come together I had to employ some clamps. I covered the clamps in aluminum foil too so they don't get covered in body filler.

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    There's a round piece in the front center of the helmet that will eventually contain an LED. I cut a circle from sintra and hot glued it the forehead piece of the helmet.

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    I probably should have done this a lot earlier. The two cheek pieces are not totally identical because of it being cut out with a Dremel and I can't make perfect cuts with it yet. So I used my original paper template and made two sintra templates which I sandwiched together and finished the edges together so they're more accurate.

    [​IMG]



    I'm currently in the stage of heat forming them to the actual cheek pieces so I can get the cheek pieces to match these templates. That should make the cheek pieces more symmetrical with each other.
     
  13. nick daring

    nick daring Sr Member RPF PREMIUM MEMBER

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    Re: Cyborg Ninja (Metal Gear Solid)

    Great job! I'm a big mgs fan and it's awesome to see this come together.

    Nick
     
  14. kialna

    kialna Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    nice. I like such builds a lot!
     
  15. BlackKaos

    BlackKaos Well-Known Member RPF PREMIUM MEMBER

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    Re: Cyborg Ninja (Metal Gear Solid)

    Looking really good! Not sure if you would but can you post the pep file for that?
     
  16. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I'll update the first post with a link.
     
  17. crabra comander

    crabra comander Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Thats gotta be one of the best suit designs from MGS. Good choice!
     
  18. STEALTH

    STEALTH Sr Member RPF PREMIUM MEMBER

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    Re: Cyborg Ninja (Metal Gear Solid)

    You are not really building this costume....

    This is my favorite character of the whole Franchise.

    Keep going! I'm tuning in for this.
     
  19. Venjix

    Venjix Well-Known Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    You don't like Snake, or Big Boss, or ... Otacon? :lol
     
  20. Ruddigger

    Ruddigger Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Any updates?
     
  21. nick daring

    nick daring Sr Member RPF PREMIUM MEMBER

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    Re: Cyborg Ninja (Metal Gear Solid)

    Yeah, I want to see more too.

    This is really off to a great start!

    Nick
     
  22. loco lord

    loco lord New Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    we want more! looking great so far :D
     
  23. Sandman0077

    Sandman0077 Sr Member

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    Holy crap that's great work!
     
  24. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Sorry for the lack of updates. I've been busy so the progress has been kind of slow. It took a while to find a good method to get the cut parts realigned properly but that's thankfully done. I'm currently working on all the detail areas where all the sensors go. I hope to get pictures up in the next few days.
     
  25. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Sorry again for people who have been following this. I've been quite busy lately but I should have more time after my exams this week. Expect somewhat more regular updates in the next few weeks.

    So leaving off from the last post, I then heat formed the sintra templates to the actual cheek pieces so I can get the cheek pieces to match these templates. That made the cheek pieces more symmetrical with each other.

    [​IMG]

    Here's the forehead piece with the sintra circle from earlier. It was hot glued into place and then skimmed with body filler to create the bevel.

    [​IMG]

    For the "bondo squish" method I use a brush and some chapstick to coat one surface, apply some body filler to the other side, and press together. The side with chapstick comes off without any body filler sticking to it.

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    Here's the forehead piece connected to the back of the helmet. The connection made between those two pieces is really quite nice thanks to the above method.

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    Mockup of the pieces together. The cheek pieces still need to have the central eye area cut out.

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    I cut out some sintra pieces.

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    Which are then hot glued in place and then skimmed over in body filler before being sanded down.

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    More body filler followed by more sanding.

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    Detail shot of the central eye area. Still needs a bit of work on the cheek pieces. It needs to be widened up a bit to match the top.

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    Cutting out some more pieces out of sintra for the smaller sensors.

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    Here are some of those sintra pieces fit in place. They're pressure fit for now.

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    I had to cut some of them in half where pieces come apart. These were hot glued in place and skimmed with body filler to create the bevel. All of these pieces are sunk 1/8" - the thickness of a the sintra I'm using (I used a circle of sintra as a gauge).

    [​IMG]

    I realized that the center line wasn't actually straight in the back so I had to redraw it. Coincidentally the pentagon wasn't symmetrical so I just redid all of those detail areas. Two layers of masking tape makes it a bit easier to work along.

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    The lines were cut using a dremel with a cutoff wheel and a steady hand. I went back over it with a small hand file to clean it up. The circles were marked using a drafting template from an engineering class.

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    Circles cut out using a dremel.

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    Sintra circles inserted and hot glued in place.

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    Again, skimmed in body filler. I find it's easy to use a utility/hobby knife after it sets to trim and clean it up (for me is about after 10-15 minutes). Timing will vary based on how much hardener you use but it's best to carve when it's firm but before it fully cures.

    [​IMG]

    Another test fit of all the pieces together. This should be the final iteration. Every time I make some small change it messes with the fit of the pieces and this time when I corrected the lines where the pieces meet on the side (namely where the cheek meets the forehead piece and the back of the helmet) it really messed it up. It took me about 2 hours to get the fit to this level. Referencing some earlier images it seems like the fit isn't quite as good but I think at this point it'll still work fine.

    [​IMG]

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    Back of the helmet. The top hole contains a piece of 1/4" acrylic rod which is what the small sensors will be made of.

    [​IMG]
     
  26. PepMaster

    PepMaster Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Looks very nice, I'm planning to sculpt the pieces (including a latex jaw piece) for Raiden from MGS Rising as soon as I finish this Cobra Commander that I'm doing for someone.
    BTW, you should really look into molding the pieces of this seperatly and doing a run of castings in the JY I know I for one for be intrested.
     
  27. loco lord

    loco lord New Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    sweet work there :D waiting in excitement for the finished work :D
     
  28. Sisko4

    Sisko4 Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Wow, looks aweseome!

    I hope that my Build comes along that nice!
     
  29. made007

    made007 Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    looks really awesome, your gonaa do the whole suit or just the helmet?
     
  30. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Yes the plan is to do the whole suit. I've got some progress on the sword which I'll post later on. I also have pretty much all the materials for the suit so I'll be working on that after I get the helmet done.

    Also just out of curiosity would people be interested if I made plans to cast the helmet? I'm also not totally sure about the protocols but am I supposed to do that only in the Junkyard?
     
  31. nick daring

    nick daring Sr Member RPF PREMIUM MEMBER

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    Re: Cyborg Ninja (Metal Gear Solid)

    Have you seen the new action figure coming out from Play Arts? Yoji Shinkawa changed up the design a little bit.

    [​IMG]

    [​IMG]

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    [​IMG]

    Nick
     
  32. Wes R

    Wes R Legendary Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Man that figure is going to be so hard to find it won't be funny. This build is awesome as he was my 2nd favorite character in the game aside from Snake.
     
  33. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Nick, I've seen most of the images of that figure (it's my first time seeing it with the face though). I did research for a few months before starting this and boy was it a pain. There's so many different versions of Cyborg Ninja out there and none of the various versions of the figures seem to really match well with the game model. I decided to stick closer to the source material, meaning the game and the drawings found in the art book. The problem is that even in the art book the character is slightly different than the one in the final game. Plus they made some slight changes between the original PSX version and the Twin Snakes version.

    I actually spent about 1-2 hours going through all my references a few weeks ago to try to get a good idea of what the sensors even looked like. They have a slight lip to them in the figure shown above but none of the images from the game or art book show that detail. That's why I decided to just stick with acrylic rod that will have a flat surface instead of that lip.

    I'm taking a slight liberty with the plan for the helmet sensors. In the games it seems like only the central eye ever lights up but on the cover of VR Missions it looks like the other sensors are lit as well. Maybe it was just their way of coloring them red but I figure they should light up. Anyways, getting ahead of myself right now - first order of business is to finish up the helmet before worrying about lighting haha.
     
  34. PepMaster

    PepMaster Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Just so you know, if you do plan o molding and casting helmets, it will be best to do that before doing any lighting.
     
  35. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I assume it's best if I make a INT thread in the Junkyard to gauge interest correct? Can I make a thread with the current state of the helmet or does it need to be closer to completion?
     
  36. Wes R

    Wes R Legendary Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I'd wait until it's done or closer to it before you do the interest thread just in case something goes wrong.
     
  37. Solochaser

    Solochaser Well-Known Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    oh no...so disappointing there isn't more photos of your epic build! Please keep them coming. This is gonna be so cool.
     
  38. Sandman0077

    Sandman0077 Sr Member

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    Leave the interest for the junkyard. I got flagged for doing that outside of there last year. Don't want to see this badass thread locked or something crazy ;)
     
  39. breakpoint

    breakpoint Member

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  40. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Yeah I think that's the cosplay most people are familiar with - it's Omi Gibson. Her dad works in movies or something like that so it's kind of unfair since it's not like she does all the work herself.

    Also, went ahead and made an INT thread in the JY.
     
    Last edited: Dec 14, 2011
  41. yoopees

    yoopees Active Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    My god I am jealous and envious of your talents! I'm a HUGE MGS fan, only reason why I bought a PS3 was for MGS4...hahah

    I will follow this until it's complete. Are you going to make Gray Fox's Helmet only or are you also going to do Raiden's as well?
     
  42. bluerob

    bluerob New Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Looks amazing!
     
  43. PepMaster

    PepMaster Sr Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    That's true, if you want the file for Raiden's Helmet I have it.
    EDIT: Ah hell here's the file.
    MGS Raiden Helmet.pdo
     
    Last edited: Dec 15, 2011
  44. Solochaser

    Solochaser Well-Known Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I like the build but the eyes look a little to big. They are more thin in the game.
     
  45. Yellowjacket

    Yellowjacket Well-Known Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Fantastic! This one is going to be amazing.
     
  46. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Only Gray Fox. I've only played the first MGS, maybe someday I'll actually get around to playing the rest.

    Thanks but for now I don't have plans for Raiden. Maybe someone else will be able to put it to good use.

    Hmm, I can kind of see that now too but I designed all the lines based on the art from the art book since it shows all the different views. I specifically measured the eye height based on relationship to the central eye so maybe the central eye is a tad large as well? But then again, in some of the art the width of the eye slots are just so far apart that it wouldn't have been possible for him to see out of. Another thing is that a lot of the times you see him in game his head is tilted down so that might make the eyes look even more narrow.

    Either way I don't think I'm really planning on changing the eye height at this point. Besides, with the current height I can see out of it pretty well whereas if it was thinner it would start obscuring vision. The last thing I want is for someone to have to lead me around when I'm wearing this because I can't actually see out of it.
     
  47. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I've been working the last few days on several rounds of filling, priming, and sanding. It's been sanded up to 600 grit wet sanding so it's very smooth. I have a link to my JY interest thread a few posts up so if you're interested PLEASE reply in that thread. I don't have a set price since it's kind of pending how much interest there is. I'm also not sure how much this kind of piece normally goes for. It's difficult to compare this to something as mainstream as Iron Man or Stormtrooper helmets in terms of both demand and output.


    Pictures of the completed master.


    [​IMG]
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    [​IMG]
    [​IMG]
     
  48. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Quick update: For those who have not checked out the interest thread yet, I'm setting the price for casts at 150.

    I just placed an order for all the mold making materials, only the best: Rebound 25, Smoothcast 65D and Plasti Paste. That stuff is expensive so I went ahead and ordered the gallon sizes of everything to save a bit on cost.

    Just to double check with you guys, I can only use NSP clay when working with Rebound 25 since it's a silicone rubber correct?
     
  49. jackhellcrow

    jackhellcrow New Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    Please show us how u are going to make it open in the face. \o
     
  50. pandamajik

    pandamajik Member

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    Re: Cyborg Ninja (Metal Gear Solid)

    I'll be using neodymium magnets since it's easier than designing a sliding hinge system. I know it's possible but in the interest of time I think magnets will be the faster method.

    I'll try to get some pictures up later tonight but so far I've got all the pieces covered in Rebound 25. I'm going to wait a full day for it to fully cure before applying the mother mold. I've got 4 layers of silicone rubber on there (print coat, 2nd coat, 3rd thickened coat, 4th normal coat to smooth final surface). That should be enough right? It's on thick enough that I can't see the color of the primer through the silicone anymore (it was still visible after the 2nd coat).

    Also, are there recommendations on sizing and height of registration keys? I made some that are about 3cm thick and I also made some using a paint palette but those round ones are only about 1.5cm thick. The thicker ones started out as round pucks but I cut them down into halves and quarters.
     

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