incredible hulk costume build

As I stated when I posted the original thread for this, I am making the sub structure/exo skeleton first and foremost. I want to know it functions before wasting my time putting skin to it. I will be likely making it in two halves, along with a prosthetic mask that I will put on before slipping my head through the kneck. The upper half will have a backpack type support so that a majority of the upper weight will be supported by my body. the lower half will be mainly the stiltsand will strap to my legs once I've slid them in. Once the legs are on, I plan to have attach points to attach the upper and lower halves (from the inside of course) to achieve extra stability. that and so the pieces don't bounce around. For the Muscles I will be using anchor points that will attach to the substructures, My goal is to make this as hollow as possible for weight and cooling purposes. So the muscles will basically be just a "fairing" similar to the skin panels on a car. Looks solid, but if you know anything about cars, you know that it's actually just a thin layer. But I will be sculpting the muscles from foam and attaching them as seperate pieces. My theory is that this will allow them to somewhat move as I move giving somewhat of a muscle ripple effect. So long as I can get the silicone skin thick enough to resist ripping and stick to major parts. like the knee caps, elbows, wrists. Then the flexing of everything else should give a pretty cool effect. What do you think?
 
These are all pretty much theories, as I've never EVER attempted to do anything like this. Though I've put a lot of thought, along with some research into figuring out how to do it. Originally I had thought about using a fake head, like mikescostumes.com did, But I think it'll be much cooler if I can actually look at you with green hulk eyes (contacts) :p and move my mouth and make his mouth move. (My mouth won't be visible, I'll likely have fake hulk teeth over where my lips would be) Don't know, maybe my ideas are too extreme. But I seem to be getting pretty good support on the matter so far. Harmonic_distortion is doing a hulk build as well, I recommend checking his out. He has already made some actual attempts at it, and has been gracious enough to share some things he has came across while doing the research. I look forward to seeing his version.
 
Hey buddy. Thanks for the shoutout. I'm really enjoying having someone to talk about this with. I promise I'm not trying to hog the thread, it's just fun to brainstorm with someone of a like mind.

Here's a interesting tidbit. As far as the skin goes, my dad (feels funny to say since I'm 39) just got a Wagner power sprayer for $148 and I put some liquid latex in the cannister. It comes out thin and even...just like a dream. Theoretically you could do a coat of even an 8 ft hulk suit in under a minute for one coat. That's encouraging.

Smooth-On has a silicone thinner that I'm hoping would lower the viscosity of silicone to the point of making it sprayable. Even if it doesnt, the texture of the latex, coupled with how thin it is might really really make silicone unnecessary other than for texture or tear-resistance reasons.

On your topic of doing the muscles separately, one of the early pieces of advice I received over on the Effects Lab was to cover each muscle group in spandex so that they would slip and slide like "normal" muscles around and over each other...and then presumably (I say presumably because they didnt finish the thought) to cover the whole thing again with another spandex suit.

Love your art man!
 
Hmmm, that's an idea harmonic, I never thought of that. If you put the spandex over the entire thing as well that would also likely help with the skin movement. Hmm not bad. Wonder if silicone would stick to spandex lol. I've started to draw out the skeletal system, I believe I've decided to go with molded plastic, or if I can find a company that does 3d printing cheap enough I'll likely have them print out at least some of the more complicated shapes. The ball joint for the shoulder for instance, unless it changes the upper arm portion is kind of warped and twisted so that it wraps around my upper arm. I did this so I could freely move the arm in the full range of motion without trying to break my arm in the process. Lol if I go plastic, I'll probably use more bungees instead of hydraulics for assisted movement. Not only will they be lighter, but the way I'm engineering he designs it'll be easy to repair/replace if they break, or wear out. The hand will be fun to sculpt lol, its getting a little more complicated. So unless I can get them printed it'll be somewhat difficult to sculpt and mold. But not impossible. Though the components for the hand should be small enough that I could buy one of those desk top printers and print those out myself. Once I transfer them to a 3d program of course. (This will take some practice) lol not something I've done before. Can't be too difficult though.
 
Oh, harmonic, thanks about my art, wait till I put my newer stuff up. Haven't updated in years. And I agree, its great to find others that have similar interests. I had no idea there was so many groups of people into this. It was always just an idea to me, I just knew it was possible. Im from Wichita, KS so haven't really had much personal access to this kind of thing. I think they finally have a few small anime and comicons that come through there
 
As many on this forum can attest, a lot can be done with desire and an eye for detail. I'm excited to see your finished suit.
 
Yeah, Mithredates. Everyone has to start somewhere. Sometimes the attention to detail can be a pain in the ass. Specially since I wanted to be a comic artist...I always tend to put SOOOO much detail in my drawings that it loses a stylistic flare. But I've been working on that, and I'm getting my own style established. Went to Comicon Sunday, talked with Eric Basaldua (EBAS) He's one of my favorite artists. Has an amazing style. Though I love his style, and I want to be as good or "better" I don't want to be a copy cat artist and take his style. So I'm working on having something just as cool, only different.
 
Sorry for the strayed discussion lol. As for my suit, I'm still doing sketches of the skeletal structure. I'm going to try and upload the sketches I have so far. They're on my phone, so I have to send them to email then pull through the computer.
 
here's some of the sketches I've done. The BASIC design of the arm has changed some. You can somewhat see it in the full body shot of the skeletal structure.
 
I love your designs,very artistic and beautiful! With plans like this I have no worries that this build will come to light!
 
Thanks, and Campbell it is pretty extreme. I just hope I'm not too crazy. Lol things will change along the way I'm sure. The only reason I'm putting so much into it, is because i kind of hope this can lead to more of a career than a hobby. If it turns out to be just a hobby, itd be an expensive one. All be it a fun one. Im pretty impressed with a lot of the stuff I've seen people making on this site. I just hope that in the end i can make something that will get as much appreciation.
 
Im trying to think about how exactly I'll use the muscles. The current train of thought is either making a fiberglass or semi hardened shell that will attach to the substructure, with carved foam muscles on top. Or I like the idea Harmonic gave me about wrapping the foam muscle pieces in spandex like material and attaching them. Only thing I can think of that would be negative about this method is I'll have to build a shielding over the moving parts, where as if I make the shell with soft muscles on top, it'll keep the "flesh" material to a min. But may add weight, and might make the movements stiffer. Though I do have an idea of making the shell pieces at a minimum just to hold he muscles where I want them, and then having only soft pieces of foam where the joints are. Who knows. May use a combo of the ideas.
 
That's cool, never seen it. Its impressive what geeks can come up with. Lol combine a little fan action, with creativity, and effort.
So with the hulk, I'm almost certain that i have the main design for the skeleton. Though it will likely have minor changes. Still trying to figure out how to make the stilts so i can bend at the knee without wearing out my legs holding me up. Lol
Also, im now debating on trying to aim for the movie hulk, or comic hulk. Movie hulk isn't quite as bulky. Would probably be easier. Though artisticly will create a pretty nice little challenge to make it look like the movie. Will likely go with a cross of the looks. I loved the second movie, but hulk wasn't as built as in the comics.
 
Yea, 7'6 would be plenty big...lol im already 6'3, compared to the average folk id almost be plenty tall, but im aiming for at least 7' would be more imposing. 8' even better, but for me the most important thing is proportions. And freedom of movement. Due to costs and timeframes I may have to simplify my designs, but haven't found out what the 3d printing would run yet. I can carve them by hand but that'll take a lot longer, and I already work 70 hours per week. If I simplify it, I'll likely use PVC, which has tons of adapters, and fittings that could be used or modified to accomplish my goal, but I don't think it will function as smoothly as my custom design. I need to take a trip to the library, and Barnes and noble soon to get some books on engineering and design. Learn a few things that'll help with the process. My girl says im obsessive about this, lol im sure she's right. But that's how I am with most things I do. I have always prefered to make the extra effort to do it right, instead of taking shortcuts. But time is no mans friend. So may have to sacrifice in order to complete it. If possible id like to have it done by next march for the emerald city comicon
 
hopefully soon Chimmera. I just recently moved into a townhome with a good size garage, been taking care of a few things getting settled in, and preparing for my son that's due in May. But I'm going tomorrow to look through some books at barnes and noble for some books on mechanisms and such. trying to find a good shop table to work on, then I will start toying around with a few of the ideas. I also need to find some books/programs that deal with cad, so I can design the build on the computer before spending the time and money on prototypes that may not work as planned. I figure using the programs will help me reduce the time it'll take to design and test. Since I can test the range of movements using that, and if it's off simply adjust it until it's right, then I can make a physical Model.
Does anyone know any companies that do 3d printing? I want to buy one of my own, but for the moment I'm not sure it'd be cost efficient considering when the job I have is done, I will likely be either moving back to Kansas, or traveling to another job. (I'm an aircraft contractor so I go where the money is)

One thing I will likely start in the next month or so though is the prosthetic mask. I am going to attempt to make one similiar to the SPFX masks you can find on youtube. something that will be fairly easy to put on and take off in a relatively short time. But I figure this will be a SOLID piece I can produce even before I get the exoskeleton designed and built...Actually Might help with the proportions part considering I can only make the mask so big before I wouldn't be able to get the face to move with my facial movements.
I usually feel a little crazy when I talk to people about this, but after some of the amazing stuff I've seen on here, I know that I'm not the only one. :)
 
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