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  1. RPF Premium Member SchubroProductions's Avatar
    Member Since
    Dec 2007
    From
    Louisville, Kentucky, United States
    Messages
    479
    Aug 22, 2011, 6:43 PM - My Buzz Lightyear Costume (progress pics) #1

    I offered my local zoo to create a new Buzz Lightyear costume since their last one was basically a jumpsuit filled with polyfoam. I decided to make it out of EVA foam. I used pepakura files and rescaled several PDF breakdowns of his armor. Once I shaped the pieces with with a heat gun I glued them up with hot glued and sealed them with several layers of modge podge. I then painted with Krylon fusion and sealed them again with a high gloss polyacrylic. Here are some of my progress pics.
  2. Member Since
    Jun 2011
    From
    UK
    Messages
    2,160
    Aug 22, 2011, 7:43 PM - Re: My Buzz Lightyear Costume (progress pics) #2

    That is ridiculous!!!!
    And yet, one of the coolest things I've seen!
    But are you a genius or a head case? I think the former....with a bit of the latter for good measure!
    I am subscribing to this thread like..........NOW!!!
    AWESOME!
  3. Member Since
    May 2010
    From
    Atikokan
    Messages
    2,123
    Aug 22, 2011, 9:07 PM - Re: My Buzz Lightyear Costume (progress pics) #3

    Can't wait to see more, very interested in hwo you will do the main body.
    nice work.
  4. RPF Premium Member SchubroProductions's Avatar
    Member Since
    Dec 2007
    From
    Louisville, Kentucky, United States
    Messages
    479
    Aug 22, 2011, 9:14 PM - Re: My Buzz Lightyear Costume (progress pics) #4

    I have the chest plate scaled two 203% which is set to my 6 foot 2 frame. I have it mounted to two sheets of poster board. I took a round plastic tub for storing toys and duct taped the sides which pulled it together to make a more oval shape. I plan on mounting the poster board to that to draw the main torso part and going from there. More pics to come of the forearm pieces and cod piece.
  5. Hamsterstyle's Avatar
    Member Since
    Jun 2009
    From
    Seattle, WA
    Messages
    370
    Aug 22, 2011, 9:29 PM - Re: My Buzz Lightyear Costume (progress pics) #5

    You've made two of the pieces I haven't yet.

    Woohoo for more Buzz costumes!
  6. clonesix's Avatar
    Member Since
    Sep 2002
    Messages
    2,312
    Aug 22, 2011, 9:46 PM - Re: My Buzz Lightyear Costume (progress pics) #6

    Oh, this is beyond infinity! Looking forward to more.
  7. RPF Premium Member STEALTH's Avatar
    Member Since
    Jan 2010
    From
    Canada
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    2,753
    Aug 23, 2011, 11:38 AM - Re: My Buzz Lightyear Costume (progress pics) #7

    this looks really good so far.
  8. CyberPaddy66's Avatar
    Member Since
    Feb 2011
    From
    Cornwall, UK
    Messages
    304
    Aug 23, 2011, 11:56 AM - Re: My Buzz Lightyear Costume (progress pics) #8

    Love it, can't wait for the top section
  9. Hamsterstyle's Avatar
    Member Since
    Jun 2009
    From
    Seattle, WA
    Messages
    370
    Aug 23, 2011, 10:36 PM - Re: My Buzz Lightyear Costume (progress pics) #9

    I don't know if this is helpful. But I just found some Transparent Ball Halves at display and costume for 20 bucks.

    They are lightweight and are exactly what I was looking for. Hope that helps you find something similar down there.
  10. RPF Premium Member SchubroProductions's Avatar
    Member Since
    Dec 2007
    From
    Louisville, Kentucky, United States
    Messages
    479
    Aug 23, 2011, 10:50 PM - Re: My Buzz Lightyear Costume (progress pics) #10

    Those halves are great. Just what I was looking for. Here are some more pics of my finished forearm and belt/cod piece.
  11. thomdave's Avatar
    Member Since
    May 2011
    From
    Los Angeles, CA
    Messages
    133
    Aug 23, 2011, 11:03 PM - Re: My Buzz Lightyear Costume (progress pics) #11

    Schubro,
    This is going to be AWE-some!
    Can hardly wait to see the finished product.
    Thom
  12. Hamsterstyle's Avatar
    Member Since
    Jun 2009
    From
    Seattle, WA
    Messages
    370
    Aug 23, 2011, 11:55 PM - Re: My Buzz Lightyear Costume (progress pics) #12

    Very nice, I'm building my cod piece and upper arms tonight.
  13. Nap59's Avatar
    Member Since
    Aug 2011
    From
    Olympia, WA
    Messages
    6
    Aug 24, 2011, 5:27 PM - Re: My Buzz Lightyear Costume (progress pics) #13

    You are doing an awesome job!! I am a noob here and have been scouring the internet for ideas to make a Buzz coustume for my kid's party next month. I also plan to wear it for the upcoming Halloween season.

    Forgive me if I ask a question that is answered somewhere else...What is EVA foam and where do you get it? Does it come "smooth" like that for painting or did you have to seal it with something? I bought some "camping mat" type foam and it is dimpled. Id rather use something smoother if it is easy to come by.

    Any other step by step instructions are appreciated! I have till the 15th! times ticking for me.
  14. RPF Premium Member SchubroProductions's Avatar
    Member Since
    Dec 2007
    From
    Louisville, Kentucky, United States
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    479
    Aug 24, 2011, 7:35 PM - Re: My Buzz Lightyear Costume (progress pics) #14

    I buy my EVA foam at the Harbor Freight Store. It comes in a pack of 4 sheets and has jigsaw edges. One side is textured and the other is smooth. I've seen people create everything from Iron Man armor to Mass Effect Armor and more with this stuff. I usually seal it with several coat of modge podge before painting it with Krylon Fusion.
  15. Fullmetalsam's Avatar
    Member Since
    Jan 2010
    From
    Quebec, Canada
    Messages
    170
    Aug 24, 2011, 9:05 PM - Re: My Buzz Lightyear Costume (progress pics) #15

    Nice work !!!
    I've been considering Buzz for a little while now and it's nice seeing how you're doing it (and how it looks in EVA foam).

    The green paint color seems to be perfect - what are you using exactly ??? (color name (since you're saying you're using Krylon Fusion))

    Those ball halves are also freaking awesome (thanks Hamsterstyle for posting the link), they really cheaper than the one I was considering and they'd be the perfect size (well I had figured I needed something along the line of 20'' dia... and the bigger ball halves are 18'' - I can make it work)
  16. RPF Premium Member SchubroProductions's Avatar
    Member Since
    Dec 2007
    From
    Louisville, Kentucky, United States
    Messages
    479
    Aug 25, 2011, 5:17 AM - Re: My Buzz Lightyear Costume (progress pics) #16

    I'm just using white gloss Krylon Fusion and a Green Apple Acrylic paint I found at Hobby Lobby. I've run out and have to buy some more soon. The high gloss polyacrylic is what I use to spray on give it it's shine.
  17. Member Since
    Aug 2011
    Messages
    20
    Aug 25, 2011, 11:10 AM - Re: My Buzz Lightyear Costume (progress pics) #17

    Ive been wanting to attempt this cause my 4 year old is crazy about Buzz! Any chance you would be willing to share your rescaled pep?

    Looking good so far, Im looking forward to seeing the chest piece myself.
  18. RPF Premium Member
    Member Since
    Jun 2011
    Messages
    768
    Aug 25, 2011, 11:28 AM - Re: My Buzz Lightyear Costume (progress pics) #18

    Oh sweet! I've been wanting to do a Buzz suit for awhile now, great for charity events and such. Looking forward to seeing it.
  19. Hamsterstyle's Avatar
    Member Since
    Jun 2009
    From
    Seattle, WA
    Messages
    370
    Aug 25, 2011, 12:13 PM - Re: My Buzz Lightyear Costume (progress pics) #19

    SchubroProductions said: View Post
    I'm just using white gloss Krylon Fusion and a Green Apple Acrylic paint I found at Hobby Lobby. I've run out and have to buy some more soon. The high gloss polyacrylic is what I use to spray on give it it's shine.

    I actually mananaged to find some Lime Green spraypaint and Blick Art Supplies up here in Seattle. Montana Gold Acrylic is the brand. The paint flows crazy well and is pretty low smell ish.
  20. Nap59's Avatar
    Member Since
    Aug 2011
    From
    Olympia, WA
    Messages
    6
    Aug 26, 2011, 7:06 AM - Re: My Buzz Lightyear Costume (progress pics) #20

    I've begun my build starting with the extremities. Now I am a little lost as to where to begin with the chest piece. How should I begin to get the right fit for the under rigging??

    Have you begun your chest piece yet? I'd live to see some step by step pics if you have...
  21. dropshipbob's Avatar
    Member Since
    Aug 2000
    Messages
    3,224
    Aug 26, 2011, 9:37 AM - Re: My Buzz Lightyear Costume (progress pics) #21

    SchubroProductions said: View Post
    I usually seal it with several coat of modge podge before painting it with Krylon Fusion.
    Is this so the paint doesn't eat the PVA foam?
  22. indiefilmgeek's Avatar
    Member Since
    Apr 2011
    From
    Knoxville, TN
    Messages
    955
    Aug 26, 2011, 9:48 AM - Re: My Buzz Lightyear Costume (progress pics) #22

    dropshipbob said: View Post
    Is this so the paint doesn't eat the PVA foam?
    You usually use modge podge (or 2-part epoxy) to harden the non-coated foam. You can use it with or without Plasti-dip (which is what most folks use to provide a solid and paint-able surface.

    If there is still flex in your foam pieces, a coat or two of Adhesive Promoter between the 'primer' level (modge podge or epoxy) and the final coat of paint will allow the enamel paint to bend a bit with the foam.
  23. indiefilmgeek's Avatar
    Member Since
    Apr 2011
    From
    Knoxville, TN
    Messages
    955
    Aug 26, 2011, 9:52 AM - Re: My Buzz Lightyear Costume (progress pics) #23

    Chris Fields said: View Post
    Oh sweet! I've been wanting to do a Buzz suit for awhile now, great for charity events and such. Looking forward to seeing it.
    Dude, you'd make an awesome Buzz! You should totally put this build on your list of things to do (after the Capt America projects, of course!).
  24. Snarkticon's Avatar
    Member Since
    May 2010
    From
    Alvin, TX
    Messages
    301
    Aug 26, 2011, 10:04 AM - Re: My Buzz Lightyear Costume (progress pics) #24

    Very awesome! Nice work so far, Schubro! I'm looking forward to seeing the torso.
  25. MattH101's Avatar
    Member Since
    Jun 2011
    From
    Oregon
    Messages
    12
    Aug 27, 2011, 12:09 AM - Re: My Buzz Lightyear Costume (progress pics) #25

    awesome start. This looks so promising!! Subscribed!

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