Lord Reign's Sith Inquisitor in works (pic heavy)

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Lord Reign

New Member
I have begun construction of A Sith Inquisitor set from SWTOR. I am modeling the suit after the concept image below. This is my first ever attempt at any sort of Pepekura / foam/ whatever else this is build. I have costume sewing experience but that is it. I gladly welcome any comments or advice on the project. Also a special shout out to a few people who have made resources and techniques available that I have learned from: Fierfek,StewYZF750, Moose, and Stealth & Del Ray from the Hero tutorials.

pic 0 | Flickr - Photo Sharing!

I first started with sketching out the 4 pieces I would need to construct the shoulders. I then cut the pieces out of EVA foam, used a foam edge cutter to angle the edges, and hot glued them together.

pic 1a | Flickr - Photo Sharing!

Next, I decided I wanted the Shoulders to have some extra strength to them and to feel more like “armor”, so I decided to Bondo them. (This may later prove to be a mistake, again this is my first attempt at any of this and is real trial and error right now.) I had tried using Smooth-Cast 321 but was not happy with the test results using it. Shoulders are Bondo’d and sanded down.

pic 1b | Flickr - Photo Sharing!

pic 1c | Flickr - Photo Sharing!

pic 1d | Flickr - Photo Sharing!

I do not sand them completely smooth because I want this suit to have a weathered and used look to it. Also you can see a Sith helmet I am also making in the background in that last photo.

Next, I decided to apply a layer of Plasti-dip, probably an unnecessary step.

pic 1e | Flickr - Photo Sharing!

After the Plasti-Dip dries for 24hours I apply a base coat. I use Rustoleum “Hammered metal” for the base coat.

pic 1f | Flickr - Photo Sharing!

After that dries I apply my black and red paints to the piece. Agai I want it to look like a used piece of battle armor so I did not want the paint to look perfect, I wanted it to be very rough, almost primal looking. He’s way to busy killing Jedi to worry about smooth trim paint lines J

pic 1g | Flickr - Photo Sharing!

pic 1h | Flickr - Photo Sharing!

The shoulder’s construction now complete I move on. Next, I designed the front, rear, and side belt boxes. They were then cut out of “Foamies” and hot glued together.

pic 2 | Flickr - Photo Sharing!

pic 3 | Flickr - Photo Sharing!

pic 4 | Flickr - Photo Sharing!

pic 5 | Flickr - Photo Sharing!

pic 6 | Flickr - Photo Sharing!

pic 7 | Flickr - Photo Sharing!

I made a mistake in the side belt boxes as I thought the hoses also went through them but they only go through the front and back belt boxes. I have decided I will replace them later if I do not like the way they look.

Next I design and construct the Forearm guards much in the same way I did the shoulders, just a little smaller and with the wrist indention.

pic 8 | Flickr - Photo Sharing!

pic 9 | Flickr - Photo Sharing!

pic 10 | Flickr - Photo Sharing!

pic 11 | Flickr - Photo Sharing!

I have decided that for the rest of the suit Bondo is really not needed, so the pieces are plasti-dipped and after drying they are painted.

pic 12 | Flickr - Photo Sharing!

pic 13 | Flickr - Photo Sharing!

pic 14 | Flickr - Photo Sharing!

pic 15 | Flickr - Photo Sharing!

pic 16 | Flickr - Photo Sharing!

pic 17 | Flickr - Photo Sharing!

I add a few LED lights to the front belt box. I may add some to the other pieces at a later time.

pic 18 | Flickr - Photo Sharing!

Now I begin on the hard part, the torso. I sat in front of my laptop for hours sketchy up various ways to build it.

pic 19 | Flickr - Photo Sharing!

I finally decide the best way to build it is to build a tank top out of foam first then add the various layers on top of that base. I realize that my office trash can makes a pretty good torso mannequin so I use it, I had a duct tape mannequin but it exploded.

pic 20 | Flickr - Photo Sharing!

And that’s where I am now, in the designing stage of the torso, more to come soon…

*********************03/10/2012 UPDATE******************
Started work on the torso.

A whole lot of measuring, sketching, second guessing, measuring, cutting, gluing and measuring.

Torso body


torso with sculpt lines drawn


Detailing progress


Detailing done


Booze: Scruffy lookin


Shoulder bell next to torso.


Shoulders are going to be attached to torso via canvas strap at the top, and elastic on the sides, each glued to the under side of the shoulder and torso. This will make them secure but mobile so I can have full range of motion.

Added buckles down the right side. The idea was with them there i could dress myself completely, but that didn't really work out...

*********************03/31/2012 UPDATE******************

Had attached buckles to the right side. Didn't like it, so I ripped out the entire right side and re-did it. The buckles are now in the back.

The main torso piece is now wearable and has been Plasti-dip'd.





Began construction on belt.


***************April 2nd Update*********************

Finished the shoulder bells. Right now they are attached to the torso via a strap and velcro, but will be glues on after the torso is done.


"Finished" the belt and the flaps but they are way to big. Obviously the concept art is not to human scale and I did not reference my belt boxes when measuring the belt and flaps. So I am just going to trim down the belt and flaps so they are the right size, a little annoying and will cost me a fair amount of time, but that's the price you pay for not checking EVERYTHING first.


Began work on the cowl. Measured and drew the design on graph paper, then transferred that to card stock paper for durability. The cowl is not going to be as hard as I thought, although it did take a few hours to finish the drawings. The cowl will also run down the back of the torso covering the buckles. The cowl will be velcro'd to the torso at the shoulders and back to keep it in place.


Designed the back plate that will go on the back torso portion of the cowl. It will be a raised box with recessed details, and will probably light up as well. I am going to scrap the bar graph in the bottom right and extend the vents in the bottum left acrross the entire bottom.


After the torso is finished and painted, and the belts are re sized, all that will be left are the skirt ant the flaps that drop down in front of it.

More to come later.....
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Active Member
lookin' good brother! i was wondering if/when someone would do something like this, so i'm really excited to see how it turns out!

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