TDK Foam Pattern, Design, Costume Build. ( PIC Heavy)

Discussion in 'DC Costumes and Props' started by Sonjou, Feb 15, 2012.

  1. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Hello everyone, First time here and poster. Been a lurker for awhile.

    A little bit about me. Name is Mark I work at a movie theatre and do a lot of movie promotions. I have been numerous heroes over the years some good costumes some not so good.

    This year i will be working on a Dark knight suit made with foam.

    But it is hard to find patterns online so by grabbing tons of reference images and some ideas from other foam builds I started making a pattern for TDK.
    As I make the pattern I will post more images then eventually the costume.

    I cannot take all of the credit though.

    I found the front Chest template somewhere and i cant remember who created or what forums it was on. (probably these) If it was anyone on here i will give you total credit.

    Edit*

    Found the person that made the chest pattern.

    Egon

    http://www.therpf.com/f24/dark-knight-foam-styrene-done-pics-120227/index2.html


    This is all a work in progress so bare with me as i try and complete all of this. i will post what I have done so far.
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    Tools

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    Dremel Tool (not sure if i will this)
    Bought from walmart $36
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    Hot glue gun
    Bought from walmart $7

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    Heated craft carver/pen thingy
    Bought from walmart $11


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    Scissors(already owned)


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    Sharpie (already owned)


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    Knife (already owned)

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    ===================================================


    Material List

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    Foam interlocking tiles 2x2 1/2" thick $0.99sqft
    Bought from http://www.foamtiles.com

    I got six tiles for a total of $24 Free shipping


    Flat side

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    Ribbed side

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    Cape 3 yards $8.00 per yd 3 yards plus shipping $33
    Bought From spandexworld

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    Mesh Under Suit 3 yards $7.50 per yd plus shipping $32.50
    1571 Medium Poly Mesh
    Bought from Seattle Fabrics


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    This is the chest and back, i haven't decided how I'm going to separate the pieces and put them together but this is the design so far.

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    Next is the gauntlet.

    Now with these they are to scale for me and separated on two sheets . i just need to add a few more pieces to add to the elbow pad.

    I made a paper mock just to test the scale. so just some scotch tape and paper and scissors.


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    Good for paper not foam


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    paper tests

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    *Edit (new design for foam)


    ===================================================


    Foam Templates

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    Gauntlet




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    Neck

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    Shoulder


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    Triceps, and straps


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    Legs


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    Abs

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    Chest


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    Collar

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    First cuts (no glue yet)

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    Questions comments all Appreciated. or if anyone has any patterns that I can edit or use would save me some time thanks.
     
    Last edited: Mar 11, 2012
  2. DJDARYO1982

    DJDARYO1982 New Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Very nice bro!!! how are you planning to do the cowl?? foam ?
     
  3. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Not foam i have an old batman mask probably rubies. I will modify it to make fit better.
     
  4. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Updated first post with materials, and some new designs on the gauntlet.

    My previous Design worked for folding the paper and taping. but due to the thickness of the foam the edges are not needed.
     
  5. SantinoCasas

    SantinoCasas Active Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Hey Mark this is looking great man, looking forward to seeing how this turns out.
     
  6. Berserk

    Berserk Well-Known Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    I'm working on one of these at the moment, what are you looking at for the under mesh?
     
  7. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Still looking into that.
    I'm not going for accuracy. The people that are here at the promo will see and know that it is batman. so with that said.

    I'm looking for an inexpensive material. I got a swatch form one company but it looked good on the site. but when I got it the mesh pattern was way to small.

    so I found another company I have a swatch coming so hopefully it will be good.

    I will post the pictures and cost once I get it in.

    Also updated the top post with tools and there prices.
     
  8. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Updated first post,

    Added Neck pattern

    and neck paper test.
     
  9. ironspider

    ironspider New Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    very nice work
     
  10. ironspider

    ironspider New Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    joanns has a nice aqua mesh that will work for the undersuit
     
  11. Wookieefoot

    Wookieefoot New Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Nice! Those heat knifes work great for cutting out the foam pieces. Wish I would have checked Walmart for one. I had to drive all over town to different hobby stores trying to find one.

    Looking forward to more, keep it up!
     
  12. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Good to know they work well with it. haven't got anything done this week. busy at work and home. but prob tonight should have some more progress.
     
  13. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Update*

    Top post updated i got my fabric in for the mesh suit.

    Prices and length updated also.
     
  14. ironspider

    ironspider New Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    very nice build
     
  15. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Thanks
     
  16. the_batdemon

    the_batdemon Sr Member

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Nice build. You're linking to the hacked site, though. I'd change the link to therpf.com so others don't accidentally go there.
     
  17. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    thanks for the heads up i didnt even realize it. thats the page i had bookmarked.
     
  18. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Updated first post.

    Added patterns for shoulders and triceps, and straps.

    I made a paper test .

    I have not tried the pattern on foam yet. but i believe it should work.

    I started on the leg patterns, I hope to have paper tests and patterns up tomorrow.

    thanks
     
  19. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Updated first post with leg patterns.
     
  20. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Updated first post.

    Ab patterns, ab straps, Chest patterns.
     
  21. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Re: TDK Pattern, Design, Costume Build. ( PIC Heavy)

    Updated collar/shoulder/chest pattern.

    and paper tests
     
  22. ugameenough

    ugameenough Active Member

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    i think u should use 1 or 2mm foam sheets and double it up to make it bulky or make it in layers.. but what do i know lol jus sayin lol other than that lookin good.
     
  23. ugameenough

    ugameenough Active Member

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    my bad u did layer it out lol sorry
     
  24. Egon

    Egon Well-Known Member

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    Those are some nice looking gauntlets!
     
  25. jayyeare

    jayyeare New Member

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    This is a sick pattern, I may use some of the ideas here to make a decent Robin or Nightwing costume!
     
  26. Egon

    Egon Well-Known Member

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    Woah! I wish I had had your talent when creating my suit. The shoulders and back look amazing. I had a helluvah time trying to get it somewhat accurate and functional (something I came up very short in doing) and yours looks killer!
     
  27. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    They are all free to use.

    I got the shoulder bells foam done and the Abs, I started on the chest. I Just need to take some pictures. and continue on. I got side tracked by working on Dye Sub patterns.
     
    Last edited: May 22, 2012
  28. carl9149

    carl9149 Well-Known Member

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    Hey Sonjou...do you ever SLEEP lol, great work pal!!
     
  29. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    I sleep about 5-6 hours a day lol .the rest is family time, drawing and video games , and work.
     
  30. joee

    joee Active Member

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    This is awesome. I may be doing tdk asap. this is a huge step from where it was originally posted. I may do another post for mine. if you are willing we could keep it as one thread for future ideas. cheers!
     
  31. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Post away, I still have to sew the mesh suit part, and finish the other parts.
     
  32. jusdust

    jusdust New Member

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    Sonjou....
    I was wondering what size paper you printed your patterns out on???
     
  33. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Letter 8x10
     
  34. jusdust

    jusdust New Member

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    Thanks man... I am gonna start on my suit this weekend... I am building my suit on an old full body wetsuit... Thank you so much for the patterns and what an amazing job you did on them... I will take pics of my progress this year, I wish I would have done that last year... I was the Tinman last year because my daughter wanted to be Dorothy. I was pretty amazing and this year she wants to be batgirl!!!
     
  35. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    Yea i got sidetracked with doing dyesub suit patterns lol, I really need to finish this.

    Nice wish I had a wet suit to add it to. that would look really good with the foam.
     
  36. Egon

    Egon Well-Known Member

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    updates??
     
  37. joee

    joee Active Member

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    Ditto! can't wait.
    question. I noticed different updates. are these patterns up to scale? if not does anyone know rough proportions?
     
  38. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    They are to scale for me. the image that is on the sheet is exactly the size I needed. I am 5'7 before putting on foam and cutting i would cut the paper out and test the size as for most of the pieces they should work for anyone. if you have any questions how I attach pieces just ask away.
     
  39. ashholroyd

    ashholroyd New Member

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    This is coming along great. Will definitely be keeping an eye on this. I'm doing something similar so we may be able to help each other along. Looking forward to seeing the end result!
     
  40. maoa2121

    maoa2121 New Member

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    Hey mate, please show some pics of the actual suit, how is comming along so i can see how to use the patterns pls :)
     
  41. bleahhh

    bleahhh Active Member

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    Wonderful!! Any chance of a belt n cowl template for foam?
     
  42. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    I never made a belt or cowl,

    On a side note this project is scrapped and my chest abs, arms, gauntlets were in my car, foam , hot glue, and texas heat do not go together I had all of it in my car, was at work, 12 hours came out and all of my seams were separated. pieces all over my seat. really sucked. hard lesson to learn.
     
  43. bobhnk

    bobhnk New Member

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    Great work and usefull tutorial ;)
     
  44. BladeRunner

    BladeRunner Active Member

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    I really like where this is going but I am confused about the gauntlet foam pattern. Why are there the little pieces and where do they fit into it?
     
  45. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    that is the elbow pad area, it goes largest to smallest, you place the pattern for the largest cut it out, then place the next size on top of the piece you jut cut out, cut that out set your next piece on op of the one you just cut out, mark it and cut it out.

    you wuld then glue the pieces back together but dnt push it all the way in, and it gives it a beveled look like the actual suit.


    here are some pictures I didnt get a chance to post.


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  46. Obsidiank

    Obsidiank New Member

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    the shoulder template looks great. How do you plan to smooth out the glue lines?
     
  47. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    A hot knife, but if I ever decide to pick this back up, I would glue and squeeze the glue out the other side.
     
  48. Redbird13

    Redbird13 New Member

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    Hi I was wondering how did you assemble to chest because I'm having difficulty with that
     
  49. Sonjou

    Sonjou Well-Known Member RPF PREMIUM MEMBER

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    If my chest was still together I would take some pictures but its not. it all came unglued,

    another point to add, on the chest it would help if you use foamies with creating this as well as the car foam. on the chest gluing and cutting the thick pieces was a little challenging
     
  50. joee

    joee Active Member

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    what cowl is that?
     

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