Gray Fox MGS1 Build

Mach1matt

Member
Hey guys. Got a few suit updates. I sat down the other day and really wanted to try and make the spine. I started out with a rough measurement and dividing it into equal sections on some card stock and cutting it out.
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I bought some foam dowels and ripped it down the middle with my band saw.
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I then transferred it to some 10mm EVA and cut it out. I beveled the back side of the “vertebrae” and left the center full thickness. The spine will cover the zipper of the suit perfectly once I attach Velcro to it. It’ll also Velcro under the neck cover of the helmet. I still gotta clean it up with my dremel but I’m happy with it.
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I then moved onto making the shoulders. Pretty much just made free hand templates with aluminum foil and duck tape in two halves. I ran out of 5mm EVA and couldn’t get more at my local Joann’s. Turns out Michael’s had rolls of 4mm and 6mm in stock locally. I used 4mm for the shoulder details.
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I ran out of time tonight before I could contact cement the right side details onto the right side.
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I plan on either moving onto remaking the neck piece or working on the back after I finish the other shoulder. Maybe I’ll do the biceps. I haven’t decided yet. I’ll update again as soon as I can. Thanks guys!
 

Mach1matt

Member
Hey guys. Sorry I haven’t updated much in a while. Work has been busy as I recently got a promotion and I haven’t had a lot of free time. Although, I’ll have full days on Sundays to work on this thing from now on. I did make a little progress though in the last month.

I finished the right shoulder piece and attached with Velcro.
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I then used tin foil and duck tape to start remaking the template for the front of the neck.
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I then cut it out into 2 halves and transferred to 4mm foam. I heat shaped it and glued the 2 halves together.
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I added some velcro at the top of the spine and under the neck plate of the helmet. I’ve yet to attach the spine to the suit as I’ll need assistance to ensure it’s positioned properly. Besides, it’ll cover up the zipper of the under suit.
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I then made a foil/tape template of the left side rib piece and transferred to 4mm foam as well. It’s not currently attached. I need to heat form some “muscle” detail into it first. I also started working on the bicep.
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Last Sunday I spent a full day creating templates for the bicep and making it. It was A LOT of trial and error but I’m pretty happy with how it’s turning out. It’s made of 6mm foam.
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I apologize for the lack of progress but it’s about to ramp up. I made templates for everything that needs to be duplicated so the other side should go fast. I’m also doing research on airbrush paints for this thing. I’ll try and update weekly from now on or at least when major pieces get made. Thanks guys!
 

Mach1matt

Member
Hey guys. Just a quick little update from the past week.

I started off by making the “collar bones”. I attached them directly to each pec after grinding a recessed channel. I still need to dress the edges but I think they will work fine.
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I then decided I wasn’t happy with how flat the pecs and ab plates were, so I hit ‘em with a little heat and reshaped. I may have burnt the “hook” velcro on the back but I can always replace it later. The blue paint is going to be sanded off and repainted later with an airbrush setup.
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I then moved on to finishing the RH bicep. I didn’t photograph that as it was the same as the LH one. I then started on making the elbow pieces. I tried carving it out of two layers of 10mm foam but it didn’t look that good. I ended up making them out of a single layer of 10mm foam with 7 individually beveled pieces surrounding it. My band saw came in very handy for these pieces.
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I also committed to velcroing the spine so I can move on to making the back pieces next.
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The last few days I’ve been working on the arms below the elbow. I’m still kind of scratching my head on these pieces, because of flexibility. I glued the 3 pieces together initially, but I ended up separating them.
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I’m still trying to decide what to do here. I’m trying to avoid huge gaps, but I know compromises might have to be made. Sunday, I plan on totally finishing the arms at least. I have about 10 or so more pieces to make. Then I may move on to the legs or back. I haven’t decided yet. Sorry it’s not a huge update, but these pieces have been tricky for me. Most of it is all new to me. I’ll keep chugging along and update again soon. Thanks everyone!
 

JPH

Sr Member
Hey guys. Just a quick little update from the past week.

I started off by making the “collar bones”. I attached them directly to each pec after grinding a recessed channel. I still need to dress the edges but I think they will work fine.
View attachment 1615110
I then decided I wasn’t happy with how flat the pecs and ab plates were, so I hit ‘em with a little heat and reshaped. I may have burnt the “hook” velcro on the back but I can always replace it later. The blue paint is going to be sanded off and repainted later with an airbrush setup.
View attachment 1615111
View attachment 1615112
I then moved on to finishing the RH bicep. I didn’t photograph that as it was the same as the LH one. I then started on making the elbow pieces. I tried carving it out of two layers of 10mm foam but it didn’t look that good. I ended up making them out of a single layer of 10mm foam with 7 individually beveled pieces surrounding it. My band saw came in very handy for these pieces.
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I also committed to velcroing the spine so I can move on to making the back pieces next.
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The last few days I’ve been working on the arms below the elbow. I’m still kind of scratching my head on these pieces, because of flexibility. I glued the 3 pieces together initially, but I ended up separating them.
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I’m still trying to decide what to do here. I’m trying to avoid huge gaps, but I know compromises might have to be made. Sunday, I plan on totally finishing the arms at least. I have about 10 or so more pieces to make. Then I may move on to the legs or back. I haven’t decided yet. Sorry it’s not a huge update, but these pieces have been tricky for me. Most of it is all new to me. I’ll keep chugging along and update again soon. Thanks everyone!

Make it as perfect as you can, then coat in Rebound 25 Mold Making material, and cast in Task 16 with some white pigment.
That will cost some $$$, take more time, but you can also tell "compromise" to leave.
 

Mach1matt

Member
Make it as perfect as you can, then coat in Rebound 25 Mold Making material, and cast in Task 16 with some white pigment.
That will cost some $$$, take more time, but you can also tell "compromise" to leave.
Thank you for the tip. I will look into that method if I can’t figure out anything with my current one. I don’t plan on this being the only suit I make. I already want to make another helmet, improving on things I’ve encountered making the current one. I’m thinking about investing in a 3D printer in the somewhat near future, and creating a 3D model of the whole suit from scratch. This has been the first project like this I’ve ever tried to do, so I’m kinda winging it. I really appreciate your advise!
 

Mach1matt

Member
Small update time. Only had a few hours to work yesterday, so I tidied up some loose ends.

I had to remake the upper section of the “hip plates” due to a measurement error, and joined the two pieces together. There was also a small piece in the lower corner of the hip plate I kept forgetting to add. I forgot to take a pic of it.

I also finalized the rib plates for both sides. I sketched on some “muscle” lines and used some heat to add some muscle definition.
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It’s amazing how much of a difference it made. I then added Velcro to the back. This process takes longer than making the actual piece.
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I replicated the other side and attached to the suit.
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The leg plates will be made in a similar fashion. I hate that I didn’t have more time to work yesterday, but progress is progress I guess. I try my best for a better update next time. Have a great week!
 

pengbuzz

Sr Member
Mach1Matt,

After seeing this post, I went back to read the entire thread! As a fan of the original MGS, the story of Grey Fox (all the way back to the first Metal Gear) was a tragedy, and yet he ended up becoming one of my favorite characters in MGS! Your work on this suit is just plain brilliant, and I think Hideo Kojima himself would be impressed!

Looking forward to your progress! :D
 

Mach1matt

Member
Mach1Matt,

After seeing this post, I went back to read the entire thread! As a fan of the original MGS, the story of Grey Fox (all the way back to the first Metal Gear) was a tragedy, and yet he ended up becoming one of my favorite characters in MGS! Your work on this suit is just plain brilliant, and I think Hideo Kojima himself would be impressed!

Looking forward to your progress! :D
Thank you very much for the kind words! He’s always been one of my favorites as well. This is my first time attempting a project like this, and it’s been a lot of trial and error, but I’m having fun doing it. Maybe once it’s done he will see it, haha. I’ll try and update regularly. All these pieces are made from scratch, templates and all, so it takes time. Thanks again for checking out my thread!
 

JPH

Sr Member
Thank you for the tip. I will look into that method if I can’t figure out anything with my current one. I don’t plan on this being the only suit I make. I already want to make another helmet, improving on things I’ve encountered making the current one. I’m thinking about investing in a 3D printer in the somewhat near future, and creating a 3D model of the whole suit from scratch. This has been the first project like this I’ve ever tried to do, so I’m kinda winging it. I really appreciate your advise!

You are doing a BRILLIANT JOB! You are working withing your knowledge base with great results!

Take what I say as a "recommendation," nothing else.

I am simply giving you options.

Unless you scan you body RIGHT NOW, 3D printing wont be as good as measuring off your actual body.

If you wanna make Task 16 molds, let me know if I can help. ;)
 

Mach1matt

Member
You are doing a BRILLIANT JOB! You are working withing your knowledge base with great results!

Take what I say as a "recommendation," nothing else.

I am simply giving you options.

Unless you scan you body RIGHT NOW, 3D printing wont be as good as measuring off your actual body.

If you wanna make Task 16 molds, let me know if I can help. ;)
I really appreciate that, and I did take what you said as such. I’ve been open to any and all creative suggestions and criticism from the start. I take zero offense to anyone offering input on this thing. I plan on doing a scan of myself before I make a model. I stumbled on a YouTube channel (Kamui Cosplay) at which her husband did a 3D scan of her using an iPhone in order to model and scale a piece in Blender. In all actuality, I wonder if using clay and sculpting on a proper sized mannequin would provide a better result with casting this type of suit. I’ve been browsing the forum the last hour or so and found an old build thread of “Nemesis” from Resident Evil. He did it using this method. I’ll definitely get in touch if I go down the casting route. Thanks again!
 

JPH

Sr Member
I really appreciate that, and I did take what you said as such. I’ve been open to any and all creative suggestions and criticism from the start. I take zero offense to anyone offering input on this thing. I plan on doing a scan of myself before I make a model. I stumbled on a YouTube channel (Kamui Cosplay) at which her husband did a 3D scan of her using an iPhone in order to model and scale a piece in Blender. In all actuality, I wonder if using clay and sculpting on a proper sized mannequin would provide a better result with casting this type of suit. I’ve been browsing the forum the last hour or so and found an old build thread of “Nemesis” from Resident Evil. He did it using this method. I’ll definitely get in touch if I go down the casting route. Thanks again!

Do a duct tape mannequin if you really want one. Unless you really want a 3D model of yourself
 

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