First time foam build - Mass Effect krogan soldier (NYCC/Halloween 2013)

strongrudder

New Member
Krogan are by far my favorite alien race in the Mass Effect games, and thanks to pressuring from a friend, I decided to attempt making a costume - for NYCC if I can, but Halloween for sure if I end up being unable to lug a large costume on an overnight bus. 8P

I've seen krogan treated impressively in latex before, but I'm nowhere near ready to tackle that - my last costume was the TF2 Scout, which only required me to make a foam bat look like metal. So I settled for EVA foam after a little research, which seemed easier to deal with for a newbie.

I'm now in hurry-up mode on this one, having lost plenty of work time since I started in May due to fear of failure. Here's my progress so far in images:

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Starting out, I did a lot of sketching to try and feel out what I wanted. The basic result I was going for was the krogan soldier/sentinel from Mass Effect 3's multiplayer mode. It's essentially Grunt's armor with an older krogan's head stuck on.

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I then started out with a paper prototype for the head, and used the patterns to cut out the EVA foam. Due to all the flattish planes on a krogan's head, this seemed like the best approach if I wasn't going to be sculpting and casting anything.

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I wasn't sure of anything I could sculpt that would stick to EVA foam, so I just took a razor and started carving some relief in there. Here it is with the main crest piece resting on top. +2 plastic cat eyes.

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I used a duct tape dummy to aid pattern-making (wouldn't even know where to start extracting models to try a pepakura method), and ended up making a wire cage shaped like a hump - posterboard didn't hold its own weight well enough otherwise. What I'm actually doing here is testing all the crest plates to see how far they are from the hump.

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Here's where I finally got a basic torso cage together. I had to hold the armor on at this point - the shape of the neck hole is oblong and it didn't have enough internal support - kept trying to flatten into an O shape, right off my shoulders. The crest and face pieces have all been glued together into the mask, which I think I was holding on with a jury-rigged mess of string at the time.

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My next step was to focus on the mask, because the back of the armor was proving difficult to wrap my head around. I painted the whole thing in the crest color, figuring it'd make a good undercoat for the face skin.

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And this brings me up to tonight - the finished paint job on the mask. I also added some elastic straps and buckles to the mask and armor so I can actually wear them hands-free now. Also threw together the bracers, which will need some detailing to look not-boring. They stay on my arms without sliding around, which is a good start.


EDIT: I can't figure out why attachments won't let all the images show up - is it because I'm a new member? Thanks to the power of img tags I've at least got the most recent progress visible in-thread. :b
 

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Thanks! These forums have proved a valuable resource while I've been trying to make this work.

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Just a small update tonight - made some simple three-fingered gloves and did the detail on the bracers. I'm planning for the final armor to be black.
 
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Sweeet! More krogans :D

Loving that mask, such a simple but effective technique. Stupid muggins here decided to try sculpting and casting, the head is absolutely MASSIVE. Bloody Grunt :p

Subbed!
 
Sweeet! More krogans :D

Loving that mask, such a simple but effective technique. Stupid muggins here decided to try sculpting and casting, the head is absolutely MASSIVE. Bloody Grunt :p

Subbed!
Thanks! I think I wandered by your thread a couple times while I've been lurking about. Your sculpt is looking pretty fantastic so far!

Today I worked on the problem of the krogan's neck. Every other costume I've seen used latex for this, which of course I won't be doing. I figured fabric would be the best bet, since it will have natural folds and might be well suited for the lizardy kind of neck krogan have. My first attempt was with felt -- big mistake. It was too stiff, and when I tested wearing just a little piece hanging down under the mask, it was ridiculous how quickly it got hot in there.

So today I went out and got some flesh-colored spandexy fabric, tested attaching it to the mask, and documented how it fell.

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Not bad so far! Also visible in the pictures are the improvements I made to the neck hole of the armor - gave it a bit of thickness and detail. There's a noticeable empty place in the front under the chin - I'd like to bring that up further to expose less of the neck, but I'm still working out how I want to do that.

And here how it looks in motion.
I gotta secure the hump a little better, heheh.
 

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Dope! Where are the eyeholes on that thing?
Can't wait to see how the whole thing pans out...

edit: oh wait, I see them, under the "forehead", right?
 
That's right! I made 'em a little bigger than intended by mistake, but the plus side is I can see really well out of the mask. X)
 
Nice idea for the fabric! If you want it to sit in one place and have permanent neck ligament things in the right place, you can use upholstery foam sheets glued to the back, or as a fixed understructure. I used to make mascot suits, and making soft fabric sit over body forms was kinda what I did :p
 
Ooh, I'll definitely look into that. I'm already using upholstery foam for muscles in my in-progress arm sleeves, so I don't have to get anything new. Thanks for the heads up!
 
I would have never thought that anybody could use EVA foam to make a decent Krogan head. You have certainly proved me wrong about that so I take my hat off to you. Thanks for posting your WIP pictures, it is important to be reminded every so often of the many different ways to make great costumes. I will be paying attention to your thread because I am sure there is going to be great things coming.
 
Thanks for the kind words, everybody!

I'm leaving for NYCC tomorrow night, and sad to say those periods of being stumped have foiled me - I won't have everything done in time. But! I am going to take what I get done to the con, and try to finish the rest for Halloween.

The main piece I won't be able to do are the boots, which stinks because I'll have my human-shaped knees out in the open. I'm still planning to do little spats over my shoes with the big foot claws, to at least make it feel less unfinished. :S

This means that I'll probably be hitting this thread with a ton of progress pictures after I return, since I don't have the excess time to edit any now!
 
very good! I love how u used the wire to determine the length of the hump. I am soon going to make a krogan armor set of my own! Ill take some inspiration from you! NICE WORK!
 
Thanks! I think I wandered by your thread a couple times while I've been lurking about. Your sculpt is looking pretty fantastic so far!

Today I worked on the problem of the krogan's neck. Every other costume I've seen used latex for this, which of course I won't be doing. I figured fabric would be the best bet, since it will have natural folds and might be well suited for the lizardy kind of neck krogan have. My first attempt was with felt -- big mistake. It was too stiff, and when I tested wearing just a little piece hanging down under the mask, it was ridiculous how quickly it got hot in there.

WOW! That mask/face is awesome! The face came out crazy-good considering it's just hacked out of the foam!!!! :cool TOTALLY worked!!
 
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