Elysium Kruger Exosuit WIP

Discussion in 'Replica Costumes' started by Ziga, Aug 14, 2015.

  1. Ziga

    Ziga Active Member

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    Hey guys,

    This is my first time making a costume. I started this build last year in October and I have till this year's October to finish it.
    The exo-skeleton is made mostly of styrene with some wooden and PVC pieces and of aluminium. Most of the back, arms and legs parts are done, what's still missing of the bigger parts are the pistons and forearm computers.
    The chest and back parts of the vest have a core of thin camping mat foam for rigidity and added thickness. The carabiners on the stomach are attached to reels, so they function as the ones in the movie.


    SDC15120.JPG SDC15121.JPG SDC15098 - Copy (2).JPG SDC15106.JPG SDC15132.JPG SDC15138.JPG SDC15142.JPG SDC15145.JPG
     
  2. Daniel Nelms

    Daniel Nelms Sr Member RPF PREMIUM MEMBER

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    Last edited by a moderator: Nov 8, 2018
  3. Matrix2db

    Matrix2db Active Member

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    Great detail work! How are you going to do the actuators on the front they make it hard to put your hands above your head?


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  4. Ziga

    Ziga Active Member

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    I'll make the actuators the way the ones in the movie look and see what kind of shoulder mobility I get. And if I won't be able to lift my arm above my head, I won't lift arms over my head, I guess.

    I finished the housing on central back piece and made the angled shoulder piece, which I was hesitant to do, because they're pretty tricksy. I made the first two of the actuators and they turned out pretty great. These are the cylindrical ones on the central back. The cylinder housing is PE plastic and the rod is aluminum.
    SDC15148.JPG SDC15151.JPG SDC15152.JPG SDC15345.JPG

    I also made most of the little flat bent brackets, that serve as mounting points for the actuators. I have most of the block actuators 3D modelled, so I'll start churning those out after some last dimension-checking.
    SDC15347.JPG
     
  5. Matrix2db

    Matrix2db Active Member

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    ImageUploadedByTapatalk1440369160.513568.jpg I read that the hero prop from the movie the front actuators were cast in rubber so they had better mobility for stunts ect.


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  6. guitarpirate

    guitarpirate Active Member

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    Would you mind sharing some of your mad styrene skills? I don't think I've seen anything this impressive before. Were they layered, with pieces for each layer cut on CNC, or hand cut? It's especially interesting because the quality is outstanding, but equivalent parts would cost something in the region of 8k to print - and even after that there would be finishing.
     
  7. Ziga

    Ziga Active Member

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    Yeah, my budget is nowhere near yours, Guitarpirate. The styrene for the whole skeleton plus endmills probably cost less than 150 euros. The pieces are all cut on my CNC router and are layered, because I couldn't get styrene sheets thicker than 5mm. And the parts require only minor sanding afterwards to hide the layer lines. This is actually my first styrene build, so I have no tips to share, I just cut layers on my machine and glue them together. Extra thin styrene cement <- this stuff is amazing.

    I started making the rectangular actuators out of PVC. I so wish these were just normal round cylinders, so I could make them on my lathe. But since my lathe is the only machine, that can make a nice hole, that's parallel to the actuator body, I have to drill the holes on it anyway. The rectangular actuators are just a pain to grip in a 3 jaw chuck.
    I tried to drill on my father's horizontal drill press, but it has so much RPM that I ruined two parts because of drill vibration. Then I switched to my lathe.

    SDC15365.JPG SDC15368.JPG SDC15371.JPG

    And I got a pair of camo army trousers. Not the right camo pattern, but pretty close. The actual camo that Kruger is wearing in the movie, if anyone is wondering, is South African Soldier 2000 camo. And it is apparently impossible to get a hold on. Here's a picture of the pattern:
    200px-Sandf1.jpg
     

    Attached Files:

  8. joberg

    joberg Master Member

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    Beautiful work and with minimum budget. Keep up the great work:cool
     
  9. Ziga

    Ziga Active Member

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    I don't want to be misunderstood, this build is budget if you compare it to guitarpirate's exosuit build. Actually it's more than ten times as expensive as my other builds. When is said the skeleton costs 150 euros, I actually ment just the styrene parts, without the actuators, aluminum parts, the vest ... I bought 200 euros (+shipping) worth of styrene and I'll probably use more than half of it on this build. The price of the nuts and bolts is actually also quite significant and the rod ends for the actuators alone were 100 euros.

    Anyway I spent my weekend lathing and polishing alu pistons and testing the actuators. I tried to make the length of actuator bodies screen accurate, but I'm finding, that some of them (considering how much movement I need in that area) are too long (which is okay) and some are way too short (which is bad). What I'll probably do is switch them around a bit to get better degree of movement without redoing parts. I might sacrifice a tiny amount of accuracy, but I don't mind. The rest of the suit is pretty accurate.
     
  10. clonesix

    clonesix Sr Member

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    Very clean work. Nice job.

    How big is your CNC table, and was it expensive, or did you build it yourself?
     
  11. guitarpirate

    guitarpirate Active Member

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    Can you share what CNC machine you have? It was great to see your method at work since I have no idea what I'm doing and you nailed the right approach to this kind of project immediately. It was very rough for me to come from game development discipline and convert myself into a mechanical engineer. If I didn't have the extra bit of headroom I would have given up, since I have no prior experience even in model-making. Being able to bake ambient occlusion and unwrap UVW islands doesn't help you here :)
     
  12. Ziga

    Ziga Active Member

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    My CNC machine is home-built. I used an old EDM machine as a base, because it has a nice X-Y table (although it has developed a few gremlins, probably due to wear). It's usable area is about 380×290mm, which is not as big as I would like and need. And it's pretty slow and not rigid enough. But it is an incredibly useful tool for learning and prop-making.
     
  13. Ziga

    Ziga Active Member

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    Here's the latest update. The actuators are mostly done, apart from the hip ones. That area still needs work.
    I don't have a great deal of range of shoulder movement. I can't put my arms over my head or reach far across my chest, but it's manageable.

    SDC15390.JPG SDC15391.JPG SDC15392.JPG SDC15393.JPG
     
  14. joberg

    joberg Master Member

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    Looking very good all around! As for budget, you know how it goes, despite plans the cost can climb real fast when you go for accuracy and functionality. My 2001 Space Station was budgeted at around $800, but I'm already at $1200 despite being careful. Keep up the good work and eager to see your next update!
     
  15. tmax

    tmax Sr Member RPF PREMIUM MEMBER

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    Looking good! Now you just have to shave your head and mount an interface in the back of your skull and you're good to go! ;)
     
  16. Mobjack

    Mobjack Member

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    Looks great. I especially like the work on the spine section. Excited to see the finished piece.
     
  17. Ziga

    Ziga Active Member

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    No no, it's Max that has shaved head. Kruger has a beard. Which is why I started growing a beard a month ago.

    Sorry for not updating this thread regularly guys, but I'm in a rush to finish the suit enough that it's wearable as it's supposed to debut this saturday. I've dropped the building of everything not essential like forearm computers, lights, cables, and I spend my evenings sanding and painting like crazy. I hate to rush a project like this because it makes me drop my standards, but I really want to wear it at the convention on saturday.

    And thanks for your nice comments. I really put a lot of work into this.
     
  18. tmax

    tmax Sr Member RPF PREMIUM MEMBER

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    Ha ha, right you are, I should've read the title better - Kruger not Max... just don't forget the face implants above that new beard! ;)
     
  19. CLOTHAR

    CLOTHAR Active Member

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    Nice looking build! Looks like a great CNC project.
     
  20. CZMarty

    CZMarty New Member

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    Impressive work with styrene, projects like this make me want to invest in a CNC router. I'm attempting something vaguely similar as I'd like to finish the basic parts for my exosuit in 5 week, fingers crossed that you finish before your deadline.
    Have you found a particular brand of solvent glue that works best for styrene? Or are you just using straight acetone/toluene?
     
  21. Pocko

    Pocko Active Member

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    This is fantastic. The level of finish is really impressive.

    I particularly like the lower spine section, very cool!
     
  22. Ziga

    Ziga Active Member

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    Hey. I'm doing the assembly today. Looks like the suit will be ready to wear tomorrow at the convention, but without some parts and without accessories.

    There is still a ton of parts to bolt together.
    SDC15435.JPG SDC15438.JPG

    Here's my system of stopping the pistons from sliding out of actuator bodies. There's a string going from the piston rod end through a hole in the body and there's a simple know holding it from pulling out.
    SDC15436.JPG SDC15437.JPG

    And here's a look at the inside of the abdomen piece. The buckles and the carabiner housings are attached to a styrene plate so that there's no force exerted on the soft green cover. Carabiners are DMM Shadows, they should be without the safety screw but I got the wrong ones.
    SDC15424.JPG SDC15426.JPG SDC15427.JPG
     
  23. Ziga

    Ziga Active Member

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    Here's a reminder of what the suit looks like:
    11590d1393810646-hulc-suit-worn-kruger-wetaworkshopelysiumwork090(20141202-191901).jpg 11589d1393810646-hulc-suit-worn-kruger-wetaworkshopelysiumwork088(20141202-190944).jpg

    So I got the suit finished enough to wear, but I had to rush the painting process (which not something you want to do) and the paint chipped on some parts, that were in contact. The weathering as also pretty basic. To this point this project took a little over 300 hours.
    What I've noticed only recently is that the black part of the vest - the undershirt that covers the shoulders - got really stretched due to all the weight it has to carry. Which means the arm pieces are hanging way too low and the same is true for the upper back.
    SDC15439.JPG SDC15444.JPG SDC15442.JPG SDC15470.JPG SDC15473.JPG SDC15475.JPG SDC15476.JPG

    SDC15452.JPG SDC15455.JPG
     
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  24. noble 10

    noble 10 New Member

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    please tell me how u did it i am looking do build a cod advanced warfare one
     
  25. Ziga

    Ziga Active Member

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    Ehm, I made a 3D model form screencaps, I bought plastic, shaped plastic into parts, painted the parts, attached parts to the vest I made.

    I suggest make a lot of mock-up pieces out of paper/cardboard/soft wood to get the sizing right.


    Here are the official photos from the convention.
    12088282_902175279837282_2840010925664732354_n.jpg 12096028_902175179837292_4049769190007778984_n.jpg 12141572_902175186503958_1535405759160521510_n.jpg

    The suit is sitting in a corner right now. I need a break from this project.
     
  26. noble 10

    noble 10 New Member

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    ok thx
     
  27. tmax

    tmax Sr Member RPF PREMIUM MEMBER

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    Mate, this turned out amazing!!!! Well done mate.

    Let me know when you're done with it and it can go on display in my movie room under your Angel of Verdun sword!


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