indiefilmgeek
Sr Member
After finishing my daughter's Baby Groot costume, I only had two weeks to pull off a Falcon costume for my 9yr old son. The catch... he wanted wings that 'popped' out of the EXO-7 flight system back-pack. :eek
Here's how it turned out.
And this is a look at the wings in motion!
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How I got there in two weeks...
First I started with the design on the wings. I design by trial and error, so I mocked up the wing design out of wood and paper first.
This is the test of the hinging of the wings.
I then created the wooden frame pieces out of aluminum.
I then took images of the Winter Soldier Falcon wings and modified them in Photoshop to fit the size/shape of these wings. By printing that out to scale, I had a template for the design of the parts.
For the wing material, I picked a 2mm foamedPVC. This stuff is AMAZING. Lightweight and easy to cut, but works like styrene.
I laid the printed template down over the foamedPVC and figured out what panels would have which wing parts.
That resulted in the following...
And this is the same wing - closed (folded down)
To hold the two wings I built a wooden box with two panels. Because the wings will overlap when folded, one wing will be 3" in front of the other.
Here are the wings mounted in the box...
I used the templates again to figure out where the paint colors should go and which colors to use.
...and then started taping off areas to
Once all the wing parts were painted it looked like this...
For the straps, I bought a cheap hydration pack with a waist and chest strap.
I then cut off the fancy back and just kept the straps and padding. I added LOTS of little pieces to it!
And then plasti-dipped them and painted them with a spray metallic paint.
Which looked like this when completed.
There the EXO-7 is complete and on my work table.
And here it is on my kiddo!
Here's how it turned out.
And this is a look at the wings in motion!
***********************************
How I got there in two weeks...
First I started with the design on the wings. I design by trial and error, so I mocked up the wing design out of wood and paper first.
This is the test of the hinging of the wings.
I then created the wooden frame pieces out of aluminum.
I then took images of the Winter Soldier Falcon wings and modified them in Photoshop to fit the size/shape of these wings. By printing that out to scale, I had a template for the design of the parts.
For the wing material, I picked a 2mm foamedPVC. This stuff is AMAZING. Lightweight and easy to cut, but works like styrene.
I laid the printed template down over the foamedPVC and figured out what panels would have which wing parts.
That resulted in the following...
And this is the same wing - closed (folded down)
To hold the two wings I built a wooden box with two panels. Because the wings will overlap when folded, one wing will be 3" in front of the other.
Here are the wings mounted in the box...
I used the templates again to figure out where the paint colors should go and which colors to use.
...and then started taping off areas to
Once all the wing parts were painted it looked like this...
For the straps, I bought a cheap hydration pack with a waist and chest strap.
I then cut off the fancy back and just kept the straps and padding. I added LOTS of little pieces to it!
And then plasti-dipped them and painted them with a spray metallic paint.
Which looked like this when completed.
There the EXO-7 is complete and on my work table.
And here it is on my kiddo!
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