Tron (Rinzler) Costume COMPLETE PG 2. (Pic Heavy)

[Pyrotechx]

Alright ladies and gents,

I have decided to go ahead and attempt to build a Tron (Rinzler) costume... Or I'll try to build it, give up, and paint my face for Halloween.

I have never undertaken a project like this, and I was REALLY hoping for a pepakura file to help me along the way for the helmet. Unfortunately, there are no files to be found... Well, apparently there is one for $15, but I heard it is not accurate AND I wouldnt even know where to look. So, this is going to be an interesting task to build it from scratch. On that note, I am open to ANY ideas of where to begin the helmet. I have already started a reference folder for different angles of Rinzler (see imgur link).

I believe I am basically going to start with a cardboard frame and then patch it up with cardboard pieces, hopefully getting it as close to the original as possible. I will then cover the piece in a thin fabric and give it a few coats of resin (Maybe put some resin/cloth on the inside, but not sure if the fumes will linger?). Once that is accomplished, I will put a safe amount of bondo on the outside that I can work with to add MINOR detail. I do not want this baby cracking all to hell.

I will begin this project tomorrow after work, but I am hoping to come home to some ideas that anyone may have.

Here is the link to some reference pictures: Tron - Imgur

Let me know what you guys think, and I am VERY open to pointers, since 95% of you are more experienced than I in costume building.

 

[Koras]

Re: Tron (Rinzler) Costume WIP

the hardest parts it's to built the helmet, not an easy costume to replicate, good luck!!

 

[LED]

Re: Tron (Rinzler) Costume WIP

rinzler was the best non-jeff bridges part of the movie, good luck with this costume! i'll be watching this thread.

 

[Primal]

Re: Tron (Rinzler) Costume WIP

That is going to be great, I too shall be watching this thread closely. Hope all goes well.

 

[Lee Fenix]

Re: Tron (Rinzler) Costume WIP

Don't know if this is the one you mentioned but it may be worth a look. scroll down to the tron stuff and they're selling a Rinzler helmet pep file.
Files

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

That is exactly what I am talking about. The pep actually looks pretty decent. I will continue the free hand method for now since I consider myself a decent artist and work with my hands a lot, but if it doesn't turn out how I want, I'll probably break down and buy that file and hope I don't get screwed. Thanks for posting that, Lee!

Posting some pics tonight of my current WIP.

 

[Lee Fenix]

Re: Tron (Rinzler) Costume WIP

No problem man can't wait to see how it comes out

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Boy, I am contemplating buying that pep file, because I am seriously having a lot of trouble creating a paper template from scratch... I basically have the back view and side view measured out, but I am having trouble actually thinking how I can cut the pieces out.

Has anyone heard anything about the Rinzler Pep for $15? I always figured I could find it for free, but seems damn near impossible.

Also, I might consider just sculpting this thing out of clay and pulling a mold from it, but I haven't bought clay outside of school in ages and I would have no idea where I could get it or how much it costs (Still broke).

I'm open to any ideas.

Edit 1:

P.S. - Here is the attempt to do some scaling




Edit 2:
Alright, I found a pretty crapp (in my opinion) pep file for Rinzler. Basically it will give me a base to build off of, but that is it. I am going to start on the pep tomorrow and hopefully have a pic of it done in a day or two.

Here is a pic of the base ill be building off of:


Edit 3:
One more edit to kind of give people an idea of what I mean... Visually. The other pic was taken from one of ArtFunk's galleries.

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Well, I was going to print off the Pep before work, but I haven't used Pep in so long that I couldnt remember how I scaled things down and what I even did to print it at Office Depot...

Might just buy a damn can of expanding foam, cut it up, and bondo it and make a mold off of it, because this is driving me nuts.

 

[Crimson490]

Re: Tron (Rinzler) Costume WIP

Yes!! Now you're making sense! =)
$8 Greatstuff + $20 Bondo + lots of TLC = 1 cool helmet!

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Alright guys, a small update:

JFCustom ended up unfolding a pep file for a Rinzler helmet made out of foam. I jumped right on the opportunity and I am pleased with the first results. Unfortunately I was a little messy with the glue, but overall it is pretty straight. There is a piece on the back that is not as "bulgy" as the other correct side, but I am hoping to fix this with either taking a heat gun to it and trying again or use some kind of putty.

On that note, would anyone suggest something to coat this thing to make it harder and flexible, but also able to add putty/bondo to it? I have seen some Smooth-on posts and also something else called Epsilon or something like that. Ah, well, please post any ideas if you have them, thanks!

Here are some pics:

 

[wishbon77]

Re: Tron (Rinzler) Costume WIP

thats cool dude

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Alright, decided to go out and try some different stuff on the helmet to get that glossy look, but with a little hardness to it. I tried some stuff I got at home depot, and so far the results are decent. The white stuff is drywall mud I was planning on using to just fill in any gaps I might have so it wouldnt leak through... Seems to be holding on well, and it dries pretty glassy. It has only been curing for 9 hours and the box says it is "dry at 9 hours, but takes 72 to fully cure", so we'll see!

9 hours in:

 

[littlebigm]

Re: Tron (Rinzler) Costume WIP

Looking good so far. You may not want to use filler on the helmet due to it being foam, the foam is likely to flex and cause the filler to crack and chip away. I have seen some people use several coats of PVA Glue on their foam helmets to give them a really nice shine after being painted.
Check out this tutorial, it may help: XRobots - How To plastic coat foam & expanded polystyrene prop and costume pieces - YouTube

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Looking good so far. You may not want to use filler on the helmet due to it being foam, the foam is likely to flex and cause the filler to crack and chip away. I have seen some people use several coats of PVA Glue on their foam helmets to give them a really nice shine after being painted.
Check out this tutorial, it may help: XRobots - How To plastic coat foam & expanded polystyrene prop and costume pieces - YouTube

Yea, I have seen that video before and I was JUST about to get some smooth on, but I didnt have the funds. I was skeptical about using the filler on the helmet, because I knew it would crack, but it was mainly added on the visor area that will be used for vacuum forming, so it doesnt matter all that much.

I actually ended up already using some of the filler and then putting the resin stuff over it, so far it is turning out pretty nice. The first "Surface" layer has already dried and I just put on a second coat.

Also, here is a quick action shot of the test piece. I bent it pretty far and it was actually really flexible, even 48 hours in. There is a pic of me bending it pretty far and an "after shot" of the piece. No cracks!

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

I am curious, would anyone have any idea how I could even begin to make the costume? I am not very familiar working with fabrics. I was thinking maybe I could buy a one piece and and some latex design, but I have never done that before and am not entirely sure how well that would work.

Another idea I had is to get some 5mm foam and cover it in plastidip and try to glue that onto the suit... It just looks like it would be intensely hard to do.

IDEAS?!

Pic for reference:

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Well, the second layer has dried and is looking pretty good. I think I will add one more layer and then throw on some bondo to cover anything I have missed. I am still pretty baffled as to how I am going to create a vacuum mold of the visor, because I want it to be flush with the rest of the helm and ill need to keep a lip. I wonder if I can vacuum the whole helmet and then cut the visor out... We'll see I guess

Here is an update on the helm, ignore the mess below, this is my play and storage area, haha:

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Well, smacked a layer of bondo on one side, didn't have enough time before work to do the other side.

Here is one side:

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Got the entire helmet all bondo'd up, looks a lot better without any cut lines!

My pops has been an auto tech for 30 years and has every tool imaginable, so im waiting on word of using his collection of sanders, haha... Unfortunately they are around $300-400 dollars a piece, so he is a little iffy on letting me just use them "on a Halloween project". But, once I get ahold of those ill begin sanding!

I tried sanding by hand, but after 30 minutes and a few muscle aches, I gave up... I'll at least need a sanding block.

Also printed out 3 identity discs in cardstock today (two for rinzler and 1 for my GF's costume - Corra), cant wait to get started on those bad boys. The plan is to make 3 discs and resin them to make them solid. I will also be implementing LED lights into all 3.

Makes me wish I wasn't at work

Still looking for a cheaper bodysuit, but those things are ridiculously expensive.

 

[Pyrotechx]

Re: Tron (Rinzler) Costume WIP

Not too bad so far... need to get a sander, so ill work on other things for the Rinzler costume. This is just the first layer of bondo.