Now Completed! Buzz Lightyear Build

[VinMan]

Buzz Lightyear to the rescue

This Build is Finally Complete!
See photos on page 2


Hey there, My wife and I are creating costumes for the local Fandomfest con here in Louisville. I also hope to be able to use this for Halloween and other kid friendly events.

I'm doing a Buzz Lightyear. I'm trying to be as accurate to the character as I can without stumbling over minute details that will slow the build.

It will be mostly EVA foam and other misc. found and created parts. Here is the progress.

Upper arms



Upper Torso



I have to create a slight adjustment here. The back of the neck dips to low and when I add the acrylic half dome shield to the back it will rest too low so will have to cut a piece of foam as a filler to raise the height.

 

[VinMan]

Re: Another Buzz Lightyear Build

I plan on using this Acrylic globe that I purchased from LightbulbSurplus.com as the visor.



they come in all different diameters. I measured the neck opening and 12" seemed to fit perfectly.
I am going to cut the neck off and then cut in half and mount it at a diagonal angle. I won't be operational but it will give the appearance that it is in the open position.

 

[VinMan]

Re: Another Buzz Lightyear Build

Here is the upper torso progress



the buttons on the left chest are actually all blue at the moment they were photoshopped to show how they will appear after paint
and I only have one upper arm built. The other was photoshopped on for visual reference.



I completed the addition of the piece of foam to raise the height in the back neck area. Now the visor should sit at the correct height.
the large round ball joint was created from an 8 inch diameter half round styrofoam ball I found at Hobby Lobby.



I hot glued it in place and cut out a hole for my arm to slip through. I then added a trim piece to the top to bridge the gap between it and the opening in the torso. I'll need to add a strap and clip to keep in in the right position.



The Laser decal is just printed on a sheet of paper for reference.
the laser button was a found item from the cap off a can of spray starch

 

[VinMan]

Re: Another Buzz Lightyear Build

I found a three pack of Right Gaurd antipersperant that had a cap that was the perfect size and shape for the three push buttons on the left side of the chest

 

[VinMan]

Re: Another Buzz Lightyear Build

here is a photoshopped photo for color reference



the button on the right and all decals were added in photoshop for reference as well
but it gives me a great idea of what I am shooting for.

made some progress on the lower legs
got them sealed with a coat of modpodge.

 

[HaNDiCaPZaCH]

Re: Another Buzz Lightyear Build

This is looking incredible! I can't wait to see more. Is this a pep file or free hand? If it is a file, would you care to share (source or file)? Buzz has always been a "wish I could" project for me until I can find a good solid place to start.

 

[VinMan]

Re: Another Buzz Lightyear Build

I found a pdo file for a small scale version a couple of years ago and modified them quite extensively in indesign.
you can google Buzz Lightyear paper craft and find the files.

 

[SchubroProductions]

Re: Another Buzz Lightyear Build

Excellent work as usual Vinny.

 

[Psicorp7]

Re: Another Buzz Lightyear Build

Nice looking build. Buzz is always a crowd pleaser. Great job on the found objects too. Good Luck!

 

[azheat]

Re: Another Buzz Lightyear Build

Can't wait to see the progress on this, I always wanted to do one of these!

 

[Sharkk]

Re: Another Buzz Lightyear Build

Good repurpose.

 

[VinMan]

Re: Another Buzz Lightyear Build

Hey there

It was Kentucky Derby weekend in Louisville. I live about 20 minutes from the track so my wife and I headed down for the festivities. What a scene. 164,000 race fans.

So Sunday was a nice day to take it easy and got some progress done on Buzz.

Got some painting done on the legs.

I used a 50 50 mix of modpoge to seal and help the paint to retain flexibility and some Acrylic Latex Paint from Hobby Lobby. White, Apple Green
and Bright Purple.

It takes about 5 coats to seal and cover solid but you can flex the pieces as much as you want and there is no cracking. I learned from previous errors when I tried to use spray paint to cover foam. Big mistake, cracked horribly.



After the first few coats of white.



With the green trim added to the lower legs.
Still needs a slight detail touch up to the trim
but you get the basic idea.


I was able to get the Lamp globe I'm using for the dome visor cut into sections with the help of a dremel cut off wheel and some masking tape.
Slow patient work but worth the effort.


Ta Da!



Test fit


The buttons on the side of the helmet are a little too large and too high up
so I'll have slice them off and remake them at a smaller percentage. I think I can lower them about three inches as well
But I really like the over all look of the dome visor.


I think I may use some plastic chrome door edge guard to finish the edge of the visor.

I think it will help the two pieces be more visible and help give it a more finished appearance as well.


Over all progress

 

[drjag]

Re: Another Buzz Lightyear Build

I bet cutting that dome was quite daunting! Anyway, that mod podge and acrylic latex mix is brilliant, I'll keep it in mind when I do more foam work myself; I'm sick of my foam work cracking when it flexes. Good luck with the rest of the suit!

 

[CVWcreations]

Re: Another Buzz Lightyear Build

Love the right guard buttons, very clever.

Will it be your face in the suit or a sculpted buzz face?

 

[VinMan]

Re: Another Buzz Lightyear Build

Love the right guard buttons, very clever.

Will it be your face in the suit or a sculpted buzz face?

It will be my face. I think every sculpted Buzz face I've ever seen looks really creepy.
I think having my own face will give it a more playful fun approach anyway. And Waaaaay more comfortable to wear

 

[VinMan]

Re: Another Buzz Lightyear Build

Not satisfied with some of the choices made on Sunday
so I made a few adjustments to make more accurate.

 

[VinMan]

Re: Another Buzz Lightyear Build

Hanging with the family last night with a new kitten, so just a little tweak last night.
Something that was bothering me on the shoulder. I was missing this little raised lip.




so I got out the exacto and the hot glue gun and made an alteration



After

No big detail but the little things add up

I sculpted the tear drop detail on the fore arm out of Sculpey Clay, hot glued it on and sealed it with latex
as well. Plan on using the same technique for creating the concave recess for the red laser on the other arm

 

[VinMan]

Re: Another Buzz Lightyear Build

Found the original website that helped me to create the files I used to make the foam templates.
I had to scale them up and make major adjustments but it was an awesome resource.

It's pretty cool.

Papercraft Buzz Lightyear - PaperModelers.com

 

[VinMan]

Re: Another Buzz Lightyear Build

Hey there nothing earth shattering on this build but a few updates

I added the knees to the top of the lower legs.



They are convex on the outside shaped with a flat back with the inside that is finished so that when the leg is bent the inside you don't see the diamond pattern of the foam
kinda like this


Made a serious rookie mistake and had to rebuild the lower arms because I had the tear drop shape and the laser reversed.
My work was highly scrutinized by my cat Cheddar.



This had to be switched back because I found these awesome Buzz Lightyear gloves that had a built in laser led and laser sound effect that I wanted to use.



I removed the laser from the glove and created a housing for it out of sculpey clay that I can glue into a hole cut into the forearm.



I then extended the wires and reconnected them to the glove

 

[VinMan]

Re: Another Buzz Lightyear Build

I've been racking my brain trying to figure out a system to be able to create the wings that would be operational and still conceal accurately.
I've seen a post inquiring on this before but I've never seen a workable solution.

If anyone has seen a solution to this or can brainstorm one I'd love to hear it.