Doctor Doom- New Project Build- Looking for Advice & Suggestions

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My son & I recently started building cosplay costumes, building an Ironman Mark IV as our first foam build. Since we finished that project, we both embarked on new build each. I chose to pursue Doctor Doom. Since I didn't find any patterns or templates that suited my needs, I elected to start from scratch. I modified an Ironman Mark IV helmet and kinda built it along the way, using a ton of reference photos from various apps and websites to guide me.

So, here is the first photos of the helmet/mask. I still have a few more details I want to add before I seal the foam and start to airbrush to color.

Anyways, I'm looking for any advice, tips or suggestions as I build out this project. I hope to have it completed by mid February 2020, in time for the Level Up Expo in Las Vegas. If I can enter the cosplay novice contest, I'm really looking for critique from the judges about the build and room for improvement.
 

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A quick update. I sealed the foam build last night after adding the mouth, side vent and ear details. I was a bit impatient, so I added some silver acrylic paint in the Mod Podge to get an idea what the build was shaping up to look like. I'll inspect the sealing tonight, then clean up any details before I airbrush an aluminum colored acrylic.
 

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Welcome! Two threads you could check out (one being my own - shameless plug) are:



As to templates, you’ve done well taking something you had to hand and modding it. the helmet looks very cool, by the way. Only tip I’d give you is to heat form your pieces before you assemble.

Happy building!
 
Welcome! Two threads you could check out (one being my own - shameless plug) are:



As to templates, you’ve done well taking something you had to hand and modding it. the helmet looks very cool, by the way. Only tip I’d give you is to heat form your pieces before you assemble.

Happy building!


I actually studied your build long before I embarked on my Doom build. I was really inspired by the attention to detail in the cape and how you developed your version of the mask/helmet. I read your build sequence several times, then book marked it for ideas and references.

Again, you are correct that I should had heat formed my foam pieces first. I did some heat forming to get the initial curves done, making the gluing a bit easier to align. My problem arose when I went back to heat form the entire helmet, causing my contact cement to start to separate. I learned that my use of the heat gun had to used a bit more delicate and to shape in stages. Lesson learned, but you are absolutely correct about the shape of the top of the helmet. The only reason I'm not going back in to heat the helmet up some more is that that part of the build will be covered by the hood. When I start the rest of the shoulders, arms and legs, I'm definitely following your advice.

Again, thank you for your inspiration & advice.
 
Awesome, glad you found the thread helpful. :) I know about trying to heat form after gluing, I’ve gone down that path a few times. I also hear you about the hood covering the top. The face you’ve got is so expressive, with the hood over it it’s going look very menacing.
 
This build has progressed to near completion of the upper half of Doom's body. As with most budget makers, I'm on a pace as financing allows, which always includes coupons and discounts for materials. The cape and hood were a green sheet purchased at The Goodwill Thrift Store and everything was fabricated with foam and materials like Velcro. I'm hoping to get the lower body fabricated over the MLK weekend, then rush through the gloves, belt and shoe covers. Goal is a completion date of February 20, 2020, in time for the Level Up Expo in Las Vegas.
 

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Looking good, man! I like the way you did the torso - looks like a foam base that you shaped and then covered with the green? Well done!
 
Yes sir. I wanted the classic tunic look, but show some musculature in the upper torso. I used Evil Ted’s male torso pattern, then covered the torso in green cloth attached with spray adhesive. This gave the upper body more proportion to the arms. I’ve been using various reference photos to achieve the kind of look I think suits my skill level and budget.
By the way, I stole your cape fabrication ideas from you. Mine is not as detailed, but I loved how your cape drapes across the shoulders and symmetrically attaches in the front.
I’m finishing up the legs this weekend. I had to fabricate everything from scratch here. Made my own patterns and hoping they don’t bind up too much around the knees.
 
OK, here's a bit of a build update. I've accomplished most of the build, but now detailing out many small details, such as fabricating Doom's holster, fake gun, which will conceal space for keys, money and cards. I'm close to finishing the gloves, but decided to add some rivets and maybe a detail piece to the back of the hands. I'm close to completion and just got notified that my costume has been entered in the novice division of the Level Up Expo in Las Vegas on February 23, 2020.
 

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Love the “D” belt buckle - great detail! I see what you mean about the knees - maybe if you turn the kneecaps upside down (depending on how you get on with them as is)? Otherwise, the legs are brilliant, well done!
 
Love the “D” belt buckle - great detail! I see what you mean about the knees - maybe if you turn the kneecaps upside down (depending on how you get on with them as is)? Otherwise, the legs are brilliant, well done!


Thank you. The D buckle was a weird idea. I was shopping for paint, when I saw a wooden D in a display. I bought it, then used it as a template, since it was the size I wanted for the buckle. It was purely a coincidence that the D was on display and stimulated the idea. Other than that, I was planning on fabricating a standard buckle, but the idea of the D was novel.

I also toyed with which direction to place the knee armor. I debated this many times, and eventually went with the round side up. I probably could have gone either way.

This time, when fabricating the leg pieces, I decided to have Velcro closures along the back of the thigh & shin pieces. Should I decide to take a break and need to get comfortable sitting down during a Con, I can remove them and rest up. This was extra work, but done strictly for convenience, since being in costume for a long day can get exhausting.
 
This was a test fit, which resulted in shortening the cape, trimming the lower tunic and remembering that I needed to fabricate a neck seal. I was undecided whether to go with a green cloth type neck cover, but elected to start fabricating a neck seal that has a metallic look.
Doom test fit.jpg
Doom test fit.jpg
 
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We took our Doctor Doom out to the LVL UP Expo in Las Vegas this past weekend. Able to cruise through the exhibit hall and pose for hundreds of pictures over 2 days. We also entered the cosplay contest and won the Show Coordinator's Award! He commented on the foam fabrication, which really pleased me. The show winners were all anime projects that had intricate sewing and well rehearsed skits. Since I was the only true foam build in the comics category, I really didn't have anything to compare our work to, but just getting the build out in public was fantastic!

Lastly, despite the decent visibility from the helmet, it got fairly hot inside the helmet, even though it was February. Something to consider when building helmets for cosplay contest.
 

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