Transforming Optimus Prime

MaxaMillaMalark · Jun 25, 2016

Hi everyone. I real new to the cosplay world. I've made costumes as a kid, and love details. Optimus Prime has been a dream build of mine since the cartoon first came out in the 80s. But I figured I'd take it to a higher level and get him to transform. Yes I've seen people make the same costume, but they either look really good in robot form, or really good in truck form. I've designed and figured out how to get the best of both worlds.
I don't have a whole bunch of money to get the best materials or programs to help create this beast of a build, so I'm using my head, pen & paper, and lots of guess work. I'd like to use the cheapest materials possible and Hope to have it built by nycc 2016. But that depends on if I can get the right materials for the job.

In this image, I was able get the basic function of the feet in squared form for the
base. The cardboard works great to show what I want, but it's not strong enough to
support the weight of the whole costume completed. It's too flimsy to hold up to
wear and tear. The joints are plastic rivets.

I even got as far as building the shin base, though this is when I found the cardboard's
weakness. On the base, I'm adding foam matting.

A friend gave me about 50 foam mat pieces for me to create from. By using my
scroll saw and belt sander, I made the cuts needed.

All the shin padding parts laid out

An after and before picture of gluing them to the bulk padding which is about 8 layers thick.

I've created the hands a few months ago. They're made from cardboard and
craft foam, all glued on top of a glove. I purposely designed the hands with the
squared tips just like in the cartoon and comics.

It took many hours (which I didn't count unfortunately), but I do know to make
a new pair takes about 2 weeks. I am in the process of making a more simplified version
with the weathered look on a printable pattern. Something people can buy, but after the
whole costume is completely finished.

That's the progress I have as of now. I've tried melting plastic bottles and some other plastics to only have them melt funny or curl up and shrink. All to try and find a strong replacement for the cardboard base. I really need help with finding or making another material to be light, strong, and semi flexible enough to hold up to the full weight of the costume. I plan to put so much detail into this project that every joint and moving will be covered somehow, but without using a fabric to do so. Any advice or assistance is greatly appreciated.

George · Jun 26, 2016

Hi MMM and welcome to the RPF :thumbsup
I grew up with transformers as well and remained a big fan to this day.I'm looking forward to seeing this transformable costume 'unfold'.Subscribed !

DMTDeadpool · Jun 26, 2016

Have you considered using several layers of PVA glue on the cardboard, this will give it a firmer finish yet remaining lightweight and be able to take more of a beating than regualr cardboard and foam

You will need to do this before painting, yes, but a pva coated card base will give you a stronger starting point.

Talaaya · Jun 26, 2016

You could try sintra or foam core. Sintra is a little heavier but has the advantage of being heat formable and is also stronger, if that's what you need.

MaxaMillaMalark · Jul 17, 2016

I've already built the feet bases out of wood, but i will try experimenting with it for the chest or arms

MaxaMillaMalark · Jul 17, 2016

DMTDeadpool said:
Have you considered using several layers of PVA glue on the cardboard, this will give it a firmer finish yet remaining lightweight and be able to take more of a beating than regualr cardboard and foam

You will need to do this before painting, yes, but a pva coated card base will give you a stronger starting point.

I've already built the feet bases out of wood, but will try that with the chest or arms. Thanks

MaxaMillaMalark · Jul 17, 2016

Im using foam core for the outer layer

MaxaMillaMalark · Jul 17, 2016

Ive started using plywood to build the feet's base structure. Tried it on and it seems strong enough. Had to make some mofications for toes and heel, but seems comfortable. Sorry I haven't posted in awhile, but house projects and getting other stuff finished, so I can clear up my plate to focus on the costume. Here's some progress pics ...

I ripped out the shoes from the cardboard and started creating the rear right foot

Using the same measurements from the cardboard, the shoe fit perfectly

I found staples work very well to reinforce the seams

Glued shoe to base

Double enforced the rear plate

Used metal pegs with clips for the hinges, and now getting ready to start the ankles

Cormac · Jul 18, 2016

You could try fibreglass too. you said something about "melting plastic bottles". To me that just sounds dangerous both in terms of fumes and burns. Be careful. fibreflass resin over a cardboard base should give you plenty of strenght and stay lightweight.

MaxaMillaMalark · Jul 24, 2016

Cormac said:
You could try fibreglass too. you said something about "melting plastic bottles". To me that just sounds dangerous both in terms of fumes and burns. Be careful. fibreflass resin over a cardboard base should give you plenty of strenght and stay lightweight.

I kept myself safe from the heating of plastic. Burnes myself once, but thats normal for me. And my pink dragon friend said the fumes had no ill effects on me. Lol. Im looking into all sorts of materials for the chest area. Its all still being built in my head.

MaxaMillaMalark · Jul 30, 2016

Finished one of the feet. Very pleased with how it turned out. The other foot is coming together fast since I was cutting the pieces for it while i cut this foot. Just a matter of gluing and adjustments.

Callianis · Aug 29, 2016

This is amazing. I've a stalled G1 project that I'm getting motivated to start back up again

Will definitely keep tabs on your ultra awesome project.

MaxaMillaMalark · Sep 4, 2016

Sorry it's been a month since I last posted, well with the roof leaking, the finishing of projects before winter, and some loss of motivation, it's been busy. BUT, I AM still working on it. Picking up my stride again. So here's the update so far... The feet are pretty much constructed, the one still needs a little tweaking. I have pics of models I made for the Knee and Leg, to give me an idea on how to proceed next. Now as a challenge to myself, I'm completely covering the joints withOUT using any fabric, which is commonplace among transformer and robot costumes, and for good reason. It's very complicated! Luckily I LOVE a fun challenge lol. So here they are, Enjoy!

Entire leg model

See how the knee will pull out from the thigh and calf area to make it easier to bend

Won't be able to fully move the knee all the way. Just enough to get up and down

Even the butt gets covered lol

Work in progress of the waist area

Front view of the leg's gracefulness

And covers up nice and neat

The joints will completely covered and have lots of moving pieces, and yet still be comfortable. Don't know how yet lol

Not complete, but can see how the cover will bend to accomidate the knee. I will use wood as structure, but cardboard to cover the joints

George · Sep 5, 2016

Love this thread with the brainstorming.Looking forward to any progress (and I hope your roof is fixed !)

Callianis · Sep 5, 2016

I always like the technical challenge of figuring out how something works. You're quite masterful Mr Malark. Evidently I have a lot to learn on my path to becoming a Jedi Craft Master.

I think with that knee piece that slips inside the shin when you straighten your leg might have the potential to jam. You might need some kind of guide rail or rollers/bearings to help keep them on track and gliding where they need to go.

Awesome stuff.

MaxaMillaMalark · Sep 8, 2016

George said:
Love this thread with the brainstorming.Looking forward to any progress (and I hope your roof is fixed !)

We're getting the roof worked on soon. Finally got the leak patched for now. Thanks ☺

MaxaMillaMalark · Sep 8, 2016

Callianis said:
I always like the technical challenge of figuring out how something works. You're quite masterful Mr Malark. Evidently I have a lot to learn on my path to becoming a Jedi Craft Master.

I think with that knee piece that slips inside the shin when you straighten your leg might have the potential to jam. You might need some kind of guide rail or rollers/bearings to help keep them on track and gliding where they need to go.

Awesome stuff.

Oh I'm not a master of anything. No years of experience or engineering degree, just lots of practice at seeing an image in my head and knowing how to bring it out. The railing idea is what i saw as well. This way everything moves and glides nice and smoothly. The back of the knee is actually more complicated that i found out because the flap that covers the area needs to be kept inward to look good. In the next pics I'll show what i mean.

MaxaMillaMalark · Oct 5, 2016

So much to add and tell! FIrst off, I will be showing pretty fast progress soon. There is a costume contest coming up near me with $1000 grand prize, so Im hussling to at least have optimus "look" good. Building out a plan to construct and assemble him faster. I have about 3-4 weeks, so it's not enough time to design him to transform, but be wearable. Once the contest is over, I can take him apart to modify the parts to transform. Being on vacation has helped. I've been working on him for about 8-12 hours a day! Crazy. SO here's the pics:

Rear of knee covered

The two plates slide upward as the knee bends. So far I can hid them away in the thigh and calf areas

Side view. Looks really cool

Front of knee

Thigh and waist area connected to knee. Waist needs more tweaking. Optimus has a butt so far lol

Front of knee and thigh

I figured out how to build a ball-bearing. One of my duh moments.

Two main pieces of ball-bearing

Model of ball-bearing complete

Arm contracted. Everything moves seamlessly. Front of elbow still needs to be done

Here is the arm extended. Yes, it can be straightened all the way

Elbow joint completely covered

Here's what the ballbearing looks like on the arm

Love the arm bases, can't wait to start building it out of wood

Proportions are everything

I felt like a coal miner wearing this lol

Face and jaw constructed. Jaw even moves up and down as you speak in it!

Side parts to optimus's head

The antannas were eriely easily to build, and turned out great

The head is assembled, but honestly I'm not content with the proportions, so I'm gonna tweak him a bit more

I like the progress so far. All of these parts, except for the head, will be used as patterns to rebuild them from plywood. Then the foam will be cut and attached. My goal is to post pics weekly to keep myself motivated and on track. Hope you enjoy otherwise!

George · Oct 5, 2016

Max,I wish you the best of luck to win that contest:thumbsup now bring home that prize!

MaxaMillaMalark · Oct 5, 2016

George said:
Max,I wish you the best of luck to win that contest:thumbsup now bring home that prize!

Thanks! Wasn't expecting that

Transforming Optimus Prime

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