Halloween 2016 Budget “The Martian” Pre-Schooler Costume

Beetroot

Active Member
Hi all,
Here is my attempt at “The Martian” extravehicular suit for my daughter this Halloween. This build was inspired by the team over at tested.com and there complete build but most of the reference and build ideas came from “The Martian Space Suit” thread.

http://www.therpf.com/showthread.php?t=239801&highlight=martian

As I progress through the build I will attempt to reference the sources as accurately as I can.
I have set this up as a separate build post to separate this from the highly detailed and accurate work going over at that thread as this build is both on a budget and for a child. I also wanted to highlight a lot of the issues that I encountered with this build and want others to avoid if possible.
Enough waffling and onto the build.

The suit: We are going to start with the hardest part of the build. After seeing the type of fabric used and the amount of panels on the original (tested’s video on this gives great reference) I decided (in my ignorance) to use an old wet suit. The plan was to get it cheap, spend a few minutes getting it the right colour and it would be super comfortable for my toddler to wear.
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Since the original colour and size was off I cut it down and sewed it to size. This was my first error (keep track there will be a few) the wet suit was too thick. It was difficult to sew and ended up being too hot and not flexible enough to move in. I also made the pattern too big (took me 5 months to realize as I started to early and my son didn’t grow as much as I thought he would) and that is how it ended up being my daughters costume. After finding out about a product called textile medium, an additive to acrylic paint that makes it flexible. I went to work repainting it to white.
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After getting the suit a reasonable level of white came my next great idea of using orange and grey fabric markers to add the coloured panels (instead of screen printing).

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After getting the orange complete and adding the grey I then added the “circuit” pattern using black markers. All of these markings were based on a rough pattern that I had come up with based on picture/videos of the suit.
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Next came the outlines. Obviously the actual suit is made up of many panels with hollow black piping between each panel. Not have the time (read as patience) or the correct materials I faked it using black “puff paint”. This worked ok but I couldn’t get anywhere near a crisp enough lines but gave a good overall effect.

Finally I need to add the remaining black panels. This was done by cutting out the armpits and behind the knee and hand sewing in with a stretchy black fabric. (If I had planned this better I could have done this when I sewed the initial suit).
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The Armor:

Thanks to MoviesColin and his templates for the armor
http://www.therpf.com/showthread.php?t=239801&page=11&highlight=martian
I proceeded to reduce the size and create the armor using foam floor mats, one of the first time I have used foam and definitely won't be the last. After cutting these out, heat forming them I proceeded to paint them up.
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As I was going for a heavily used suit I tried a couple techniques like using toothpaste to mask off parts of the "metal". Overall pretty happy with all these and how the came out. I ended up making spare so that I could pick and choose based on my final vision.
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Attaching the Armor and Finishing the suit:

Before I finished the suit I used velcro and add it to where the armor would be placed. I also added some grey stretch fabric down the arms which had some velcro attached to it as well. The finishing touches to the suit included a grey strap (grey ribbon was used) that the climbing harness would attach too as well as the NASA patch that I had purchased off of Amazon.
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The boots:

To attempt the boots I was originally planning on trying to find some cheap wet suit booties for my pre-school, turns out this is impossible so I settled on some plain white shoes from Walmart (can't go wrong for $5).
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Using my new found fondness for foam I attempted to craft this out of craft foam.
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This turned out great except when I added the armor my daughter could no longer get in the shoes and I had to do some last minute modifications (rip apart) to get her shoes on. The effect worked as planned. The bottom of the suit hid the top of the shoes and the armor parts hid the shoe laces.
 
Chest Harness:

This was the first time I really just freestyled with some foam. It took a couple goes to get the final shape (and even then I had to cut it down some more) and then I added details. This was all constructed out of foam floor mats and craft foam.

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I then painted it using leather paints (although looking back it would have been cheaper just to use more of the textile medium, white foam would have made it easier too). The rivets were faked by using real rivets (seemed the easiest solution) and the WesDoesStuff's ARES sticker was printed and attached.

http://www.therpf.com/showthread.php?t=239801&page=2&highlight=martian

I never bothered with the backpack as I knew it would never be worn.
 
The Helmet:
The helmet was never in the original plan, the aim was to replicate the look of Watney just before the evacuation inside the HAB. However since I finished a whole weekend early I decided to jump in. Using a 12” Acrylic light cover as my base I free formed using reference pictures and … you guess it … foam mats. This was a mistake as the helmet is anything but spherical. Since the helmet is more egg/oval shaped I fought this to the end. Turning a sphere into this shape turns out to be pretty much impossible. I soldiered on through the night and ended up with a respectful shape.
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After the shape was complete I simply spray painted until happy. The lettering was added by printing on the reverse of a stick A4 sheet that I had spray painted orange. The globe was then cut to shape using a rotary cutting bit. This took a lot of time as I didn’t want to cut too far and have to somehow repair a crack (duct tape anyone?).
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After attaching this using hot glue I covered the seam with some left over black craft foam.
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The lights we made using some travel Vaseline containers with some cut up flashlights.
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After painting these to match they were simply screwed into the foam.
The inside of the helmet had some foam added with a little left over orange and grey fabric to cover the foam mat texture.
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Some weathering and old model decals added to give some details we were good to go. In the space of a weekend I had a rough approximation of a ARES ready helmet.
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Final Parts:
To finish off the build the costume needed a couple things. The first was some sort of climbing harness. Obviously I could have tried to recreate the screen used version, however in the name of time, money and sanity I decided to purchase one for $50 that met the basic criteria, I added a NASA logo printed on a fabric transfer and glued in place. I didn't want to damage the harness in case it might be used (and I felt there was nothing to gain in damaging it).
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Next was the neck seal. This was made out of some black stretchy fabric that was just doubled back on itself numerous times.
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Finally was the snoopy cap. Since you only breifly see it in the movie and was unlikely to be seen in the pictures I followed a rough pattern using whatever scraps I had left. (This ended up never being worn as I lost this argument with my 4 year old daughter.
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When it all comes together:
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After all the hours of work this was an extremely satisfying picture to put together.
 
Photoshoot and Final Thoughts:
After finally getting this costume together I couldn't wait to take the photos. Unfortunately my daughter who initially loved the idea of this costume decided it wasn't for her and was not as willing as I had hoped when it came for the photos. In retrospective I completely went about the initial suit the wrong way. I should have started with the idea of comfort for a small child and aimed for accuracy after that. That being said this has been one of the most fun builds I have attempted mainly due to the different material used and the fact it pushed me so far. I hope you enjoyed reading this and here are the final pictures that I managed. All in their orange glory.
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This looks awesome! And yes, comfort > accuracy when it comes to childrens costumes. But nonetheless, this looks really cool.
 
Looks great, and maybe your son will be able to fit in it next year.


Sent from my iPhone using Tapatalk

Thanks for the comment, Unfortunately even though my son is 2 years younger he is already the same weight as my daughter but about a head shorter. This was one of my original design flaws, the suit requires an extremely thin build (fortunately my daughter fits that description).
 
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