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  1. SKS Props's Avatar
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    Jul 17, 2017, 7:09 AM - Gears of War Theron Guard Cosplay SKS Props Updated 8/15/17 #1

    Gears of War Theron Guard Cosplay - Hey everyone Steve (SKS Props) here with another build. This time I'm going to be taking on the Theron Guard from Gears of War! This build is going to rely heavily on my build process for the Wacraft Orc I made last year. Crazy thing is I started this build July 7 and I need to have it complete for a huge Gears group at this years Dragon Con. And if you have done the math that means I have to complete this beast in a month and a half.......hopefully.

    I also want to post that I will be streaming from time to time on Twitch so you can check out the progress there too. www.Twitch.tv/sksprops

    Lets get started wit the reference image



    For those that haven't played Gears before pretty much everyone is covered in ridiculously bulky armor and everyone works out non stop. So since I am still 5'7" I'm going to have to make some risers and a muscle suit along with some insanely detailed armor.

    Materials:
    EVA foam 3", 1/2" and 1/4" http://amzn.to/2nmYrgI
    Craft foam 1mm-5mm http://amzn.to/2n9zIfe
    Barge Cement http://amzn.to/2nn2ycQ
    Loctite Super Glue http://amzn.to/2n8RkqI
    Fleece http://amzn.to/2o99kCW
    Latex http://amzn.to/2n9CNM4
    Rubber cement http://amzn.to/2nn3yO8
    Smooth on Silicone and Resin http://amzn.to/2o9oCYk http://amzn.to/2nn1w0o
    Rattle can Primmer and Colors http://amzn.to/2ns6tH8 http://amzn.to/2mHNysW
    Liquitex Heavy Body Acrylics http://amzn.to/2o9dNFA
    Plasti Dip http://amzn.to/2o9iK1h
    Upholstery fabric http://amzn.to/2n8DlRS
    Painters Tape http://amzn.to/2o9iwaF
    Last edited by SKS Props; Aug 15, 2017 at 7:44 AM.
  2. SKS Props's Avatar
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    Jul 17, 2017, 7:17 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17 #2

    Gears of War Theron Guard Cosplay - First thing I need to do is work from the ground up. Just like the Warcraft Orc I built I will be using some really thick foam for my risers because it's extremely light, but I will also be adding some high density foam from TNT Cosplay Supply to make these a little more rigid. I have decided to use some sandals this time since the shoes were a bit tricky to get on and off with my last build, I can also adjust how tight to make these which will be perfect. So using some 3" thick foam from AM Foam in KC. I roughly draw out my shape and cut it out on a band saw. These layers are glued together suing my personal favorite Barge Cement.







  3. SKS Props's Avatar
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    Jul 17, 2017, 7:23 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17 #3

    Gears of War Theron Guard Cosplay - To keep the sandals from moving around I will be gluing them to the foam but also screwing them into some styrene that is embedded one layer down. That way there will be no chance of these things coming loose while walking around.









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    Jul 17, 2017, 7:32 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17 #4

    Gears of War Theron Guard Cosplay - At this point I start shaping the 3" thick foam with my Dremel and sanding drum. This will give the boot a gradual curve down to the detail of the sole. The sole is 1" thick high density foam from TNT Cosplay Supply, I am very impressed with how durable the foam is. Details are cut into this using a cutting wheel on my rotary tool. The front soles are attache using Barge cement and the base for these boots are good to go!

    www.Twitch.tv/sksprops









    Last edited by SKS Props; Jul 17, 2017 at 7:40 AM.
  5. SKS Props's Avatar
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    Jul 18, 2017, 6:03 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/17/17 #5

    Gears of War Theron Guard Cosplay - Boot base is built so it's time to add the armor. I use 6mm foam for the armor ring and 4mm foam to construct the top front of the boot. All of the little details on the front and sides of the boots are cut out by hand from 4mm foam













  6. Member Since
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    Jul 18, 2017, 8:26 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/18/17 #6

    Subbed before I can even see the images on works PC, looking forward to seeing this!
    ps. I saw the pics, only just started the bottom of the boots and already looking special!
    Last edited by equib; Jul 20, 2017 at 4:32 AM.
  7. SKS Props's Avatar
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    Jul 20, 2017, 6:13 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/18/17 #7

    Gears of War Theron Guard Cosplay - Boot bases are done so it's time to start moving up the leg. I use some cheap foam to make a skeleton for some 4mm foam cover. The armor that will cover the shin is cut out of 6mm foam and attached the the skeleton using barge cement. The important thing here is I didn't attach that piece to the armor covering the top of the foot. That way I have a little bit of a gap that provides more movement and helps with walking around.











  8. Ultra Lord's Avatar
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    Jul 20, 2017, 12:26 PM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/20/17 #8

    Holy heck those are some big feet!
  9. SKS Props's Avatar
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    Jul 21, 2017, 7:16 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/20/17 #9

    Gears of War Theron Guard Cosplay - Rather than adding additional layers of foam I decided to cut into the base layer with a dremel and sanding drum. This is really to keep the weight down and a lot of this will be covered up with armor. The straps are cut out of 4mm foam and the holes are burned in using a heat tool. I repeated this step for all 6 outside straps. I need 24 "hero" buckles that will be visible on the costume which is exactly how many I have. The buckles on the inside of the boots won't be seen because of a covering tabard. I purchased the buckles back in 2014 and was going to match them on the inside. But because cost would have been around $60 for buckles that would never be seen I decided just to fabricate some out of foam. This will also help in case they rub together when walking and once painted no one will ever know. Also with the lowest straps in place I can attach the armor that will cover the back of the heel.















  10. gothic's Avatar
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    Jul 22, 2017, 4:52 PM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/21/17 #10

    boots look great, im sure the company that makes New rock boots would like the patent on those
  11. SKS Props's Avatar
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    Jul 26, 2017, 7:20 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/21/17 #11

    Gears of War Theron Guard Cosplay -I cut the side and calf armor from 6mm foam and using the heat tool burned some plate lines in. I got a great deal on rope from lowes and strung is round all of the armor plates. Using real rivets I started adding all of the little details that I hope will make this costume really stand out at DragonCon. The calf armor was constructed flat then curved with a heat gun and glued into place.



















  12. SKS Props's Avatar
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    Jul 29, 2017, 8:14 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #12

    Trying to figure out which helmet I want to bring to life.

  13. Member Since
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    Jul 29, 2017, 1:38 PM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #13

    SKS Props said: View Post
    Trying to figure out which helmet I want to bring to life.
    My partner is a huge Gears of War fan, she says A. I say B!
  14. gothic's Avatar
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    Jul 29, 2017, 2:15 PM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #14

    B with D as a close second
  15. dedguy's Avatar
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    Jul 29, 2017, 9:36 PM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #15

    gothic said: View Post
    B with D as a close second
    I'm with this gothic ^
  16. Rogviler's Avatar
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    Jul 30, 2017, 12:13 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #16

    B or D for sure. They have a more unique look. You don't want to go too Power Rangers.

    -Rog
  17. LeClubNerd's Avatar
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    Jul 30, 2017, 4:44 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #17

    Absolutely awesome work.


    Also, i'm pretty sure it's D
  18. RPF Premium Member
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    Jul 30, 2017, 6:26 PM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #18

    Haven't played GoW in a long time, but D, definitely go with D!
  19. One of us, one of us! RPF Premium Member The Schlitzie's Avatar
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    Jul 30, 2017, 7:02 PM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #19

    I can't choose between B or D.
  20. SKS Props's Avatar
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    Jul 31, 2017, 8:12 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/26/17 #20

    Gears of War Theron Guard Cosplay - Preview of the chest armor I'll be showing all of those progress pics in the next day or two. The details drove me crazy!

  21. SKS Props's Avatar
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    Aug 1, 2017, 7:33 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 7/31/17 #21

    Gears of War Theron Guard Cosplay - Started building the chest by making a skeleton out of 1.5 inch foam strips. This hekp me figure out the scale without really having to worry about the details. The skeleton is skinned with 4mm foam as a base layer. Patterns for all of the detail pieces are hand drawn on bristol board again to check scale without having to build and worry about details.









  22. SKS Props's Avatar
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    Aug 4, 2017, 8:04 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 8/1/17 #22

    Gears of War Theron Guard Cosplay - Apparently I didn't upload the rest of the boot pics. So here is a photo dump showcasing how I built the rim at the top of the boots, the knee pads, and gave them some battle damage.
















  23. LeClubNerd's Avatar
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    Aug 5, 2017, 6:37 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 8/4/17 #23

    Fantastic work. Looking forward to more 😁
  24. SKS Props's Avatar
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    Aug 14, 2017, 8:11 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 8/4/17 #24

    Gears of War Theron Guard Cosplay - Sorry about the lack of updates I have been in the shop every single day trying to get this guy finished up for Dragon Con. Here are the steps I took to building up the spine and back plates. Honestly it about finding your bottom most layer and building up from there. I determined that all of the armor for the check actually starts with the back and wraps around to the front. I achieved the different heights by using 10,8,6,4 and 2mm foam from TNT Cosplay Supply.





















  25. SKS Props's Avatar
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    Aug 15, 2017, 7:43 AM - Re: Gears of War Theron Guard Cosplay SKS Props Updated 8/14/17 #25

    Gears of War Theron Guard Cosplay - These pics show how I made the base for the collar and glued it to the main chest armor.









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