UrbanTerror
New Member
So once again I procrastinated in making a new costume for Dragoncon in ATL this year. I had originally planned on throwing together a Star Lord out of things from around the house. But then I came across Jim's video on brokenreelpro's YouTube channel for his one day build Star Lord helmet. So I went about collecting all the bits and pieces for that and the rest of the costume.
I started out with the same Iron Man mask as Jim for my base and added various pieces of plastic, craft foam, PVC, and a fake baseball helmet for the back.
Plastic cut to cover original eye holes

Sketching out contours and cut lines.

Plastic baseball helmet used to create back of helmet.

Rough cuts to get sizing right for my head

Printing life size versions of movie stills made great templates.

This first mouth guard ended up being too small.
I later made a larger version and etched the lines in
with a knife for detail.

Filling in the empty spaces with more plastic.

Craft foam to build up the thickness over the ears.

Plastic Weld to sculpt the face piece. (not my best work)

Random PVC pieces to get a pretty close facsimile.

More craft foam over the PVC to smooth and add shape.

Mouth piece in place, also plastic tubing above it.

Spare craft foam on back of helmet for detail.

Roughly constructed center chin piece from craft foam.
I just kind of winged it to get it to work.

Closer View

Plastic Dip to seal all the craft foam and act as a primer.


Kind of a gunmetal metallic paint as the base color.

Masked off base color to add lighter silver areas.

Gold added last

View of the back

Some dry-brushing to weather the edges and what not.

Almost Done

Close up

I started out with the same Iron Man mask as Jim for my base and added various pieces of plastic, craft foam, PVC, and a fake baseball helmet for the back.
Plastic cut to cover original eye holes

Sketching out contours and cut lines.

Plastic baseball helmet used to create back of helmet.

Rough cuts to get sizing right for my head

Printing life size versions of movie stills made great templates.

This first mouth guard ended up being too small.
I later made a larger version and etched the lines in
with a knife for detail.

Filling in the empty spaces with more plastic.

Craft foam to build up the thickness over the ears.

Plastic Weld to sculpt the face piece. (not my best work)

Random PVC pieces to get a pretty close facsimile.

More craft foam over the PVC to smooth and add shape.

Mouth piece in place, also plastic tubing above it.

Spare craft foam on back of helmet for detail.

Roughly constructed center chin piece from craft foam.
I just kind of winged it to get it to work.

Closer View

Plastic Dip to seal all the craft foam and act as a primer.


Kind of a gunmetal metallic paint as the base color.

Masked off base color to add lighter silver areas.

Gold added last

View of the back

Some dry-brushing to weather the edges and what not.

Almost Done

Close up
