Tali'Zorah vas Normandy cosplay (in progress)

[CarrieBird]

Here are some WIP pics of my Tali costume.

My first attempt at vacuum forming!


Sizing up the pepakura! The mold I pulled the PETG plastic over is fiberglass reinforced pepakura with bondo and lot and lots of sanding. The rest of the helmet is made from EVA foam and hot glue.


Making fabric patterns, very helpful to have a dress form here.


EVA foam formed with a heat gun and coated with 2 layers of spray Plasti Dip followed by spray paint. Visor tint is self adhesive car window tint stretched over vacuum formed PETG. Lighting and fan were wired up for me by View Profile: Dracogt - the RPF


I was able to get most of this costume done in time for ACEN 2013 but still a lot I need to finish, more pics to come!

 

[mlkr]

That mask looks really good. Please do update with more photos of the whole build and the final results ^^
Great job so far !

 

[Ferro]

I'm really liking the way the helmet looks and I'm quite interested to see the final build

 

[Siliconsmith]

How well did the pep/fiber/bondo buck hold up to forming, and how thick is the PETG you used? I am working on a vacuum forming rig too and I am looking at different buck materials: going for affordable but not one-offs that break as soon as I try to form over them.

Looking good so far!

 

[CarrieBird]

How well did the pep/fiber/bondo buck hold up to forming, and how thick is the PETG you used? I am working on a vacuum forming rig too and I am looking at different buck materials: going for affordable but not one-offs that break as soon as I try to form over them.

Looking good so far!

Vivak® PETG Sheet .040" From US Plastics seems to be a good thickness, the .030" was a bit on the flimsy side. The buck held up decently with a bit of cracking around the edges which was more from me prying it off than actual pressure from the vac. Also sorry for the delayed response, just got back to this costume a few months ago.

 

[ConnertheCat]

Loving this build - she's my favorite ME character (so much so that I named my cat after her).

Are you going to attempt the eye glow (Not that I could even figure out how... blacklight? eesh!)?