Gears of War Theron Guard Cosplay SKS Props Updated 8/15/17

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SKS Props

Sr Member
Gears of War Theron Guard Cosplay - Hey everyone Steve (SKS Props) here with another build. This time I'm going to be taking on the Theron Guard from Gears of War! This build is going to rely heavily on my build process for the Wacraft Orc I made last year. Crazy thing is I started this build July 7 and I need to have it complete for a huge Gears group at this years Dragon Con. And if you have done the math that means I have to complete this beast in a month and a half.......hopefully.

I also want to post that I will be streaming from time to time on Twitch so you can check out the progress there too. www.Twitch.tv/sksprops

Lets get started wit the reference image

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For those that haven't played Gears before pretty much everyone is covered in ridiculously bulky armor and everyone works out non stop. So since I am still 5'7" I'm going to have to make some risers and a muscle suit along with some insanely detailed armor.

Materials:
EVA foam 3", 1/2" and 1/4" http://amzn.to/2nmYrgI
Craft foam 1mm-5mm http://amzn.to/2n9zIfe
Barge Cement http://amzn.to/2nn2ycQ
Loctite Super Glue http://amzn.to/2n8RkqI
Fleece http://amzn.to/2o99kCW
Latex http://amzn.to/2n9CNM4
Rubber cement http://amzn.to/2nn3yO8
Smooth on Silicone and Resin http://amzn.to/2o9oCYk http://amzn.to/2nn1w0o
Rattle can Primmer and Colors http://amzn.to/2ns6tH8 http://amzn.to/2mHNysW
Liquitex Heavy Body Acrylics http://amzn.to/2o9dNFA
Plasti Dip http://amzn.to/2o9iK1h
Upholstery fabric http://amzn.to/2n8DlRS
Painters Tape http://amzn.to/2o9iwaF
 
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SKS Props

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17

Gears of War Theron Guard Cosplay - First thing I need to do is work from the ground up. Just like the Warcraft Orc I built I will be using some really thick foam for my risers because it's extremely light, but I will also be adding some high density foam from TNT Cosplay Supply to make these a little more rigid. I have decided to use some sandals this time since the shoes were a bit tricky to get on and off with my last build, I can also adjust how tight to make these which will be perfect. So using some 3" thick foam from AM Foam in KC. I roughly draw out my shape and cut it out on a band saw. These layers are glued together suing my personal favorite Barge Cement.

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SKS Props

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17

Gears of War Theron Guard Cosplay - To keep the sandals from moving around I will be gluing them to the foam but also screwing them into some styrene that is embedded one layer down. That way there will be no chance of these things coming loose while walking around.

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SKS Props

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17

Gears of War Theron Guard Cosplay - At this point I start shaping the 3" thick foam with my Dremel and sanding drum. This will give the boot a gradual curve down to the detail of the sole. The sole is 1" thick high density foam from TNT Cosplay Supply, I am very impressed with how durable the foam is. Details are cut into this using a cutting wheel on my rotary tool. The front soles are attache using Barge cement and the base for these boots are good to go!

www.Twitch.tv/sksprops

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SKS Props

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17

Gears of War Theron Guard Cosplay - Boot base is built so it's time to add the armor. I use 6mm foam for the armor ring and 4mm foam to construct the top front of the boot. All of the little details on the front and sides of the boots are cut out by hand from 4mm foam

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equib

Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/18/17

Subbed before I can even see the images on works PC, looking forward to seeing this!
ps. I saw the pics, only just started the bottom of the boots and already looking special!
 
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SKS Props

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/18/17

Gears of War Theron Guard Cosplay - Boot bases are done so it's time to start moving up the leg. I use some cheap foam to make a skeleton for some 4mm foam cover. The armor that will cover the shin is cut out of 6mm foam and attached the the skeleton using barge cement. The important thing here is I didn't attach that piece to the armor covering the top of the foot. That way I have a little bit of a gap that provides more movement and helps with walking around.

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SKS Props

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/20/17

Gears of War Theron Guard Cosplay - Rather than adding additional layers of foam I decided to cut into the base layer with a dremel and sanding drum. This is really to keep the weight down and a lot of this will be covered up with armor. The straps are cut out of 4mm foam and the holes are burned in using a heat tool. I repeated this step for all 6 outside straps. I need 24 "hero" buckles that will be visible on the costume which is exactly how many I have. The buckles on the inside of the boots won't be seen because of a covering tabard. I purchased the buckles back in 2014 and was going to match them on the inside. But because cost would have been around $60 for buckles that would never be seen I decided just to fabricate some out of foam. This will also help in case they rub together when walking and once painted no one will ever know. Also with the lowest straps in place I can attach the armor that will cover the back of the heel.

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gothic

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/21/17

boots look great, im sure the company that makes New rock boots would like the patent on those
 

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SKS Props

Sr Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/21/17

Gears of War Theron Guard Cosplay -I cut the side and calf armor from 6mm foam and using the heat tool burned some plate lines in. I got a great deal on rope from lowes and strung is round all of the armor plates. Using real rivets I started adding all of the little details that I hope will make this costume really stand out at DragonCon. The calf armor was constructed flat then curved with a heat gun and glued into place.

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Rogviler

Well-Known Member
Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17

B or D for sure. They have a more unique look. You don't want to go too Power Rangers. :p

-Rog
 

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