My Wolverine costume build - yellow suit from Deadpool & Wolverine

[Bloop]

After some pre-planning and wondering if my sewing skills are even capable, I started trying to make Wolverine's yellow & blue suit in time for Halloween 2024:



I'm rying to construct everything myself, if I can, from boots to mask and claws, though if I get pressed for time, I'll eliminate the mask and buy whatever parts I can't finish myself. I'm starting with the pants, as it seems like the hardest part (to me, anyway). Fai warning: i I fail with making the pants, I might abandon the whole project. But I'm going to try my best.

I started trying to find suitable fabric. There's some pretty accurate yellow screen printed fabric sold by Parallel Life Stdios, but at $47/yard, it's a lot more expensive than I want to spend. I don't trust my skills enough to risk blowing hundreds just on fabric. Plus, I didn't see any blue or black fabric offered by them with the same pattern, so I"d rather get all three that match each other.

I couldn't find anything close enough, both in color and pattern, on any of the major fabric websites or Amazon's sewing fabrics. Etsy has some passable options, but nothing that I felt confident in buying "blind." I wanted a close-enough pattern, close colors, and at least a bit of stretch/flexibility.

Then I looked at my shower curtains...

...and started thinking, hey why not see if there's anything there?

A new search on Amazon found a promising prospect:

Not exact by any means, but it had a nice look, simlar pattern and is a heavier, durable woven fabric, which seemed like it could work. And it came in the colors close to what I needed: I ordered the 72" × 72" Mustard yellow, and Navy Blue and Black in 36" × 72". 72" × 72" is equal to 4 square yards of fabric, so I'm hoping it's enough of the yellow - I'm slim and I figued the pants don't need to be full length because of the boots, and I'm not planning on doing full sleeves either (maybe if I have enough tiime & material,, but I like the sleeveless look better, as it's more like the comic costumes). If not, hopefully I could order more fabric later.

Got my fabric/curtains:

The color looks close (this pic is under bluer lighting than natural light), and considering the different lighting and color in movies and photos, this looks pretty good to me. It has a nice sheen so that the diamond/square pattern varies in the light in a similar way to the screen printed movie fabric.

More to come, I've made working on the kneepads, getting close.

 

[Banzai88]

Bloop Good luck with the build. The yellow material looks good. Here's an interesting shot on construction underneath the main body.

 

[Bloop]

Bloop Good luck with the build. The yellow material looks good. Here's an interesting shot on construction underneath the main body.

Thanks, I did see that pic in the "Wolverine All Day" thread, it's a good reference. I may do a similar system to connect the top with the pants. I'm planning on going sleeveless but with the shoulder pads, so I'm not sure if I'll make the undershirt look more like the black areas on the long sleeve shirt (looks like it has some strap-type details)Not movie accurate, but more like the comics. But I may make it both ways.

In other supply news, here's the faux leather I bought for the boots and other costume details next to the fabric, and some invisible zippers I'll be using (all also purchased on Amazon). The yellow zippers are a bit light, but I think I'll only need to use one for the back of the neck, or maybe along a seam, so it won't be too visible.

 

[Banzai88]

Right--at least you know the collar is separate from the chest piece now. Found this one but no shoulder pads.

 

[Bloop]

Right--at least you know the collar is separate from the chest piece now. Found this one but no shoulder pads.

Yeah, I figured that the harder (firmer) parts were separate, like the pecs, abs and upper back, plus the over-the-shoulder pieces that connect the front and the back, but there's also that section above the pecs that stops below the upper collar. You can see it a little clearer in this clise up from the pic I posted earlier. There's a definite separation - you can see shadows, especially on the right side. The color looks a little different too, maybe just due to the weathering on the chest piece.

You can also see how the black sections connecting the shoulder pads differ from the sleeveless top - it looks like faux leather, which connects to the black version of the screen printed fabric - here's another zoomed image showing it:

It also makes me think there's actually three or four pieces to the top: the under shirt, seen in the pic you posted (which was probably long sleeved with the yellow and blue upper arms before they got cut off), then the shoulder pads, attached to the black faux leather + black fabric which may go on like football shoulder pads over the under shirt, then the top layer is the chest & back pieces connected by the "claw" stripes on the shoulders and sides, which would look more like a sleeveles t-shirt in shape.

I've also been wondering if there was deleted scenes showing how the sleeves got cut off. It almost looks like they might've been burned off, since the fabric is the blue screen printed fabric, but it turns black toward the tattered edges. Maybe there's a missing scene where

Spoiler

Pyro burns them off?

 

[Capfan94]

Yeah, I figured that the harder (firmer) parts were separate, like the pecs, abs and upper back, plus the over-the-shoulder pieces that connect the front and the back, but there's also that section above the pecs that stops below the upper collar. You can see it a little clearer in this clise up from the pic I posted earlier. There's a definite separation - you can see shadows, especially on the right side. The color looks a little different too, maybe just due to the weathering on the chest piece.

View attachment 1853151

You can also see how the black sections connecting the shoulder pads differ from the sleeveless top - it looks like faux leather, which connects to the black version of the screen printed fabric - here's another zoomed image showing it:

View attachment 1853152

It also makes me think there's actually three or four pieces to the top: the under shirt, seen in the pic you posted (which was probably long sleeved with the yellow and blue upper arms before they got cut off), then the shoulder pads, attached to the black faux leather + black fabric which may go on like football shoulder pads over the under shirt, then the top layer is the chest & back pieces connected by the "claw" stripes on the shoulders and sides, which would look more like a sleeveles t-shirt in shape.

I've also been wondering if there was deleted scenes showing how the sleeves got cut off. It almost looks like they might've been burned off, since the fabric is the blue screen printed fabric, but it turns black toward the tattered edges. Maybe there's a missing scene where

Spoiler

Pyro burns them off?

Spoiler

They show that the sleeves got ripped up during his fight with deadpool in the car

 

[Bloop]

Spoiler

They show that the sleeves got ripped up during his fight with deadpool in the car

Thanks, I missed that. It's still confusing to me why the fabric is black at the edges.

 

[Capfan94]

Thanks, I missed that. It's still confusing to me why the fabric is black at the edges.

The suit has black there. It can be seen under the shoulder pads

 

[Bloop]

The suit has black there. It can be seen under the shoulder pads

I get what you're saying, but I don't see why the blue fabric blends into the black around the frayed edges of the sleeves. Plus, the undershirt's blue/black areas don't match the same areas on the long sleeve shirt with the shoulder pads:

The black areas in the 2nd pic mostly look like faux leather and have different seams (the exception being the bottom of the pic, around the armpit, where it switches to the screen printed black material). The 1st pic is mostly blue screen printed fabric that blends into the black, frayed edges.

That's why I think the shoulder pads are attatched to a completely different undershirt (with the long sleeves) than the one used in scenes without the shoulder pads - seen here without the top/chest piece:

The shiny black, faux leather type fabric areas don't match up with the shoulder areas as seen when the costume has the full sleeves and shoulder pads. The seams are different - there's at least 4 seam areas on the long sleeve costume's undershirt (one at the top of the shoulder, a second one that looks like black piping, then a third and fourth area below that) while the cut off sleeve undershirt has only 2, which don't match in style or position.

Plus, if it were the same undershirt, the shiny black areas should extend out from under the yellow top/chest piece at the shoulder. That doesn't happen. The sleeveless shirt has only the blue screen printed fabric extending from that area, which blends into the black fabric toward the frayed edges.

It still could be possible that the shoulder pads are attached to shiny black fabric and put on over the shirt that has the cutoff sleeves, but it seems more likely to me that there were two different style undershirts made - one with long sleeves and attachments for the shoulder pads, and one with the cut off sleeves and no shoulder pads. The sleveless shirt doesn't seem to have any way to attach the shoulder pads.

 

[JLeezy23]

Nice stuff so far! The stretch pleather has to be a layer above the undershirt, similar to Deadpool's shoulder section that connects to his shoulder parts, you can definitely see a difference in height just below the yellow section

 

[Banzai88]

Bloop Some reference Ryan Meinerding posted.

 

[Bloop]

Bloop Some reference Ryan Meinerding posted.

Thanks, those are useful, though not completely accurate to the screen costume. I have a folder full of pics that I've been using - official photos, on-set pics, screenshots I took from trailers and teasers, pics of the Hot Toys figues - which helped me figure out a lot. I've been working on creating patterns.

I finished patterns for the pants today, though seeing these new pics, I'll have to make an adjustment to one pattern - the narrow strip running vertically along the back legs from the boot to the waist. The pics I had are too blurry or don't have the right angle to see it clearly, so I thought it stopped before reaching the waist.

Here's a bunch of the pics I've been amassing as references:




I especially searched for pics of areas that aren't shown a lot - particularly the back and the boots - plus anything that showed closeup detail. I noticed that the pants seem to tighten at the back, with a black strap and metal hardware peaking out from under the belt (the one attached to the shirt) in this pic:



I also found more details for the boots - there's more panels than I originally thought. I also assumed the boots used just the blue and black leather/faux leather fabric, but it appears to have the black screen printed fabric along the front, and a panel of fabric (blue screen printed or maybe mesh?) on the inside leg of each boot. I also think the boots have invisible zippers on the inside of each leg, along the seam, running down toward the ankles.

I also got lucky and found a pack of a dozen 1" airplane buckles on clearance at my local fabric store. I was thinking of 3D printing them, but these will be higher quality and take less time and work. I need 6 buckles for the front of the boots and the 6 for the side/back of the top, (seen here):



Here's the buckles and bias tape piping:

 

[Bloop]

Here's so in-progress pics of my pattern making process, and construction of the foam kneepads. Not the cleanest work for sure, but hopefully it'll get the job done. I glued eva foam to scrap fabric and just loosely covered it with another piece to test it. The real fabric is a lot thicker, so hopefully I can still get enough detail to show through.

I made the kneepads by tracing my masking tape pattern onto fabric, then I made some adjustments before scanning it into my pc so I could make a clean, symmetrical pattern.



I started trying to use myself as a mannequin, using masking tape and Sharpies to create the shapes on myself. But it's hard to work on it that way. Taking off and putting on the pants over and over added more time, and was hard to keep the masking tape intact. So I made a duct tape dummy of my legs, which helped immensely.

I had planned to make a test version of at least one pant leg with some scrap fabric, to make sure the patterns were correct and to work on my tailoring skills before moving on to the real fabric, but I forgot how long it takes to prepare each fabric piece from the patterns, so I may just jump in and hope for the best. Even though Halloween is still 2 months away, I have a lot to do to try to finish this costume in time and I have no idea how long each step will take me. I can always skip the mask, and I could also skip the shoulder pads, since I'm not making the long sleeves anyway. I suppose I could even skip the whole top if I wanted to go as shirtless Logan l, though I doubt I'd be let in a lot of establishments without a shirt, though for Halloween, they might be more lenient. I also don't quite have Hugh Jackman's physique.
I also figured that the pants are the thing that would stick out the most if they're not made right - the top is so constructed of foam pads that it might not be as easy to recognize flaws, but everyone knows how pants are supposed to fit, and can see when they're poorly constructed. And the top might not need a lot of sewing - I could easily just glue everything and get away with it, due to all the rigid, foam parts. The pants wouldn't work if I just glued them (not very well anyway).

 

[Capfan94]

 

[Banzai88]

Looks like it’s held in-place by magnets?

 

[JPH]

Bloop

Have you ever seen a show where the engineer comes up with a crazy idea that "just might work"?

So, if you figure out the size of the teeny squares on the costume, make a 3d model of the pattern, print it into 2 or 3 meter sheets then make a mold of it, and then use a rubber like Task 16, in that shade of yellow, you can make the fabric/armor/covering in a material that is yellow all the way through.

Does that make sense?

You could also just get a huge sheet of clay and try it, but it would be much more perfect with a 3d printer.

I just had the idea!

I can elaborate if you think it will help. I dont want to sabotage your quest. But you coukd use what you've made already as templates.

 

[Bloop]

Bloop

Have you ever seen a show where the engineer comes up with a crazy idea that "just might work"?

So, if you figure out the size of the teeny squares on the costume, make a 3d model of the pattern, print it into 2 or 3 meter sheets then make a mold of it, and then use a rubber like Task 16, in that shade of yellow, you can make the fabric/armor/covering in a material that is yellow all the way through.

Does that make sense?

You could also just get a huge sheet of clay and try it, but it would be much more perfect with a 3d printer.

I just had the idea!

I can elaborate if you think it will help. I dont want to sabotage your quest. But you coukd use what you've made already as templates.

Yeah, I could see that working. It's a lot mpre involved tgan I would want to get, especially because I have very little experience with mould making, especially trying to pull rubber casts.

Another option I was thinking that wiuld be less extensize (and less expensive) would be to model and 3D print a patterned paint roller with the screen printed fabric design, and just roll the design onto regular fabric and letting it dry before cutting it for sewing. Or I suppose you could roll the paint on after cutting out the pieces, which might make it easier, since I imagine it wiuld be harder to get a consistent pattern applied to larger areas, as the paint would gradually lessen with each roll of the roller.

 

[JPH]

Yeah, I could see that working. It's a lot mpre involved tgan I would want to get, especially because I have very little experience with mould making, especially trying to pull rubber casts.

Another option I was thinking that wiuld be less extensize (and less expensive) would be to model and 3D print a patterned paint roller with the screen printed fabric design, and just roll the design onto regular fabric and letting it dry before cutting it for sewing. Or I suppose you could roll the paint on after cutting out the pieces, which might make it easier, since I imagine it wiuld be harder to get a consistent pattern applied to larger areas, as the paint would gradually lessen with each roll of the roller.

The Task 16 would pull easily because the 3d print would be shallow. Just print a grid to the correct size.

You just have to make sure you pour it on a flat level surface and you could make 3mm thick rubber sheets with the pattern. You are already making the templates.

But no worries, I am just brainstorming.

Also, consider scuplting freeform air for the black mask horn/wing thingies.

I did that for an Adam Strange helmet I have been working on, and it worked out well with magnets.

For the parts that are not in contact with your face, just put some aluminum foil behind it as support...remove it when the Freeform ait cures.

Dont put Freeform air directly on your face, use a layer of Saran Wrap.

 

[Bloop]

The Task 16 would pull easily because the 3d print would be shallow. Just print a grid to the correct size.

You just have to make sure you pour it on a flat level surface and you could make 3mm thick rubber sheets with the pattern. You are already making the templates.

But no worries, I am just brainstorming.

Also, consider scuplting freeform air for the black mask horn/wing thingies.

I did that for an Adam Strange helmet I have been working on, and it worked out well with magnets.

For the parts that are not in contact with your face, just put some aluminum foil behind it as support...remove it when the Freeform ait cures.

Dont put Freeform air directly on your face, use a layer of Saran Wrap.

Thanks, I may try that. I was planning on using eva foam for the mask, with a frame of metal wire/rod (like wire coat hanger type wire) to hold its shape. That is if I have enough time after making the pants, top, boots, gauntlets and gloves (just listing it all is giving me anxiety). Plus, I want to make claws, but ideally, I want to make them retractable since 1) I don't want to have to carry them around when I'm not using them and 2) some establishments may not let me in if it looks like I have giant knives strapped to my hands. I could always make them out of foam too, to make sure they're not considered weapons.

I saw this motorized retractable design that I might be able to make work and fit inside the gauntlets. Plus it'd amp up the coolness factor if it worked.

3D Printable Retractable wolverine claws #TinkerMechanical by Niyaz

Link to the video if you want to see how this mechanism works: https://www.youtube.com/watch?v=GEGb_TDZdro #TinkerMechanical This mechanism is dedicated to one of the characters in films about X-Men - Wolverine. These "Сlaws" can be extended and retracted. To operate the mechanism, a...

www.myminifactory.com

 

[Bloop]

I just thought of something else for the mask - I could still make the surface out of foam, but make a 3D printed framework underneath (reinforced after printing for strength). That way, it'd still be lightweight, but it would be even easier to get the shape right than trying to bend wire/rod. It'd make creating the rest of the mask easier too, especially the face.