Firs timer making a Dark Knight costume for Halloween 2013 !!

[heliraptor]

Hi all,

Been a stalker here for a while and thought I'd repay my visit's here by signing up and starting a thread on my first ever costume build.

First though I have to thank guys like Obsidiank, Egon and jacksadventures for inspiration and ideas.

I decided to make the suit out of varying thicknesses of foam, 2mm, 4mm and 6mm and used a resized image to make all the templates, well most of them, some I had to guess, they may not be 100% right but they give the right impression.

I started this about 3 weeks ago, so time is moving on and I really need to stop typing and get making as the party is this Saturday !

I'd have loved to have gone the proper mesh route, but the time I had to make it simply didn't allow the research and sewing time, so I settled with a one piece under suit for diving or motorcyling off ebay, I plan to stick on the leg armour and hang the chest and abs section incl shoulders that will be held on with velcro all going well.

The belt I managed to find on Amazon and I also found a good priced cowl on ebay (Rubys) that I intend to shorten.

I have the gloves sorted, gauntlets nearly done, I also found on Amazon a set of kids gauntlets sold by Toys r us in the states, they have been modified to fit my arm and they are good enough given the time I had.

Its not gonna win any competitions, but it gives the right impression and has been fun to do.

Best get sorting some images for the work so far !!

Back soon.

 

[heliraptor]

Where it all started, making the templates and began cutting out the 2mm craft foam. Doubled up on the leg armour to give it that more detailed look.

 

[heliraptor]

Took a while to get most of the leg armour cut and templates sorted.

Once cut out they were sealed with a warm iron just to flatten the foam a little, and then coated with two coats of plastidip. I kept them light coats to maintain the flexibility without it cracking off.

 

[heliraptor]

Next was to make a start on the chest piece. I used the same printed template for the pattern, got it right on the second attempt and used the method of cutting a V section in the rear then hot gluing to give it its shape. I also prior to cutting warmed it in the oven and shaped it by pressing into a saucepan lid to give it a little curve.

The fun bit was cutting out the bat logo !!!

All plastidipped and with the addition of some carbon fibre look vinyl (4D car wrap off ebay) it looks a treat.

 

[spazzman31337]

You are doing amazing work for your first time the cuts are beautifully done so clean. I can already tell that this build is going to come out Epic. Might I ask what you used to get such clean cuts?

 

[heliraptor]

Next the gauntlets...and the discovery of the kids set on Amazon was a god send !

Started by making a rough template out of card, traced this onto foam, and doubled up to strengthen it and add features, once it was plastidipped and joined up it looked just the part, maybe a tad small but I can live with that.

 

[heliraptor]

Hi spazzman...sorry missed your post in between adding images. I cut out the templates and laid them on the 2mm foam cutting around the edge of the template a with hobby knife, kind of sturdy scalpel if you like, but kept fresh blades in as they soon get worn and start to snag. Some bits are a little rough as I'm pushed for time.

On the leg armour I cut around the smaller portion first (the bit stuck on top), then glued this to a fresh piece of foam using zap (CA glue) then cut around this leaving a border.

I found this much easier then cutting two separate parts , getting an even border would have been a nightmare.

I'll take pic of the knife if you need me to.......just let me know.

 

[heliraptor]

And onto the cape. I found a template on line and sized this up, the span is 3600mm !!!

Found some lightweight black cloth in a local store and managed to cut it in one piece. Marked it out then cut to size and its now round my mother in laws getting tidied up.

The plan is two have some wooden / carbon rod in the leading edge of the cape so can I open it up the full span....I'm such a child !!!

 

[heliraptor]

Next thing on the agenda was to finish the ab section.

Using the template I cut out the supporting foam that the abs get stuck too. This is where I'm at right now, need to finish that off tomorrow and also figure out how and where I'm going to attach supports to hold it in place around my sides.





The next few days are going to be busy busy busy..what with work as well I'm going to be pushed to get it ready.

Wish me luck, I'll post updates as I move on.

 

[spazzman31337]

Very awesome thank you for such a fast reply I'll have to get myself a hobby knife now haha. Also just a quick question how fast does zap (CA glue) dry? I have been using hot glue and it is just a tad bit messy to say the least.

 

[heliraptor]

No problem.

Hot glue is okay i some areas but like you say its thick, and bloody hot ! I burnt my finger the other day.

The ZAP glue comes in different thicknesses, thin, medium and thick, the bottle colours respectively are pink, green and yellow. The thin stuff is water thin and good for wicking between surfaces, I use the medium, drying time states around 20 seconds but on the foam after about 5 seconds its on, so you need to align it carefully before any contact and lay it on. I usually lay it on dry, draw around the edge then use that as a guide to lay it on once glue is applied.

You could use the thick and I think that would allow you more slide time if you need to adjust its position. Its nice and clean though, and doesn't eat the foam.
To apply the glue a lay a bead around the edge of the foam to be glued, then use an offcut with a flat tip to spread it out and ensure a nice smooth even coverage. If it starts to go off a little thats ok, it still sticks like mad. Best to get used to it on some offcuts.

Listen to me...sound like I know what I'm talking about !!! In reality I make it up as I go along, but if it works it works.

 

[spazzman31337]

I can't thank you enough for being so helpful heliraptor. I shall be getting some new supplies for my future projects thanks to you .

 

[heliraptor]

No problem at all, if I can help in any other way just ask. Good luck

 

[heliraptor]

Bit of an update, party is tonight, pretty much done, few areas I had to hold off on but I'll sort these next week for the next party !!!

Finished the chest section, pretty pleased with how it turned out, the side bits warp round and are held in place by velcro on the undersuit.

Didn't manage to get the neck finished or in fact the shoulder armour (

Looks good though, hopefully will get a few pics later on in the suit.

 

[LePaul]

How do you like the Rubies belt?

I have the molded one that came with the GCFX suit and while its nice, I'm curious how the other belts look

Nice work!

 

[heliraptor]

Hi and thanks,

This costume making lark is bit addictive, I'm already eyeing up an ironman tron for next year !!

The rubies belt is not too bad, I had a moulded latex belt with an old batman suit and that in comparison is very poor.

I'm home right now so will take some closer images of the belt if you wish, doesn't look too bad and is easily customised, the colour is a bit off but I ran out of time to repaint it.

The length of the belt is bit short and is connected at the rear by velcro, it would pay to actually get some old rucksack clips (The click together type) and sewing some 2" elastic to it. This would make it much easier to put on. You could of course lengthen the belt by buying two and clipping the extra links in.

If you want the pictures let me know but for the money its a good belt.

Lee

 

[Echo4Delta]

Ok... you're the man. Now expect a lot off annoying questions...

1st, can you link or give us a pic of the martial (I assume foam) you're suing for the support piece?
2nd, Yes, picture us till your fingers hurt! LoL

I did Iron Patriot for Halloween this year (2013) Now, its Dark Knight time!