Help with Realistic Muscle Suit


New Member
Hello everyone, I am a costume newbie facing a bit of a dilemma here. I am trying to recreate Gray Fox from the Metal Gear Solid series, but my primary obstacle is making a realistic muscle suit. My first thought was just getting one of those zentai suits and using an airbrush to paint on the pattern, but after viewing several examples of this, I don't like how obviously artificial it looked. Because of this, I am thinking that a better idea might be to use a zentai use as a base, cover it in a layer of liquid latex, then build up the musculature with something and coat in more liquid latex. The problem is building it up: What should I use, and how do I get the effect I want? I have heard of using upholstery foam, L200 foam, "fun foam" and all sorts of other things for making fake muscle, but I don't know what would give me the best bang for my buck. I plan to use liquid latex from Monster Makers, so I have that taken care of.

Basically, I don't want an exaggerated "superman" look like the cheap musclesuit costumes you can buy around Halloween; I want it to be sleek and look like what it is supposed to be: an exoskeleton of sorts.

As a related question, is there any way to sand down foam or latex or anything to make sure the muscles are shaped properly and aren't all blocky? What is the trick?
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