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  1. PerilloMarc's Avatar
    Member Since
    Feb 2013
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    East Haven, Connecticut.. USA!
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    1 Week Ago  Nov 29, 2017, 11:49 AM - Captain America Civil War Build Process techniques fabrication #1

    So I really wanted a Cap suit for the longest time and after making a shield I decided to just go for it.. I then realized sewing and costuming and replicating is way way WAY harder then I previously thought and became obsessed. I'll be posting periodically to update where I am in the process and what I have came up with. here are a few pictures of my 2nd/3rd attempt at making the suit and its decent but no where near what I wanted or am capable of so down the rabbit hole I go. Feel free to comment or post up your own progress too. I will post progress but also the mechanisms I design and think up along with processes I've come up with to solve my problems or processes I find useful or helpful that I have borrowed from and where you can find them also for more information on them also.. AND WE'RE OFF!

    -Thanks in advance to anyone I can't reply back too in a reasonable amount of time
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    Last edited by PerilloMarc; 1 Week Ago at 2:15 PM. Reason: Grammar
  2. PerilloMarc's Avatar
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    1 Week Ago  Nov 29, 2017, 12:01 PM - Re: Captain America Civil War Build Process techniques fabrication #2

    for the Star Burst silicone areas around the star i drew out the angles and measures and matched them until i had a template i was happy with. sizing is always an issue because we're all not 6 foot 2 so i find it best to figure out the angles and go from there when making templates. i just used hot glue to make the actually Bursts because it is what i had at the time but i will eventually mold these from silicone. i have seen the abs done a few ways, mostly with the foam backing and i just dont like the way the look (even though they do look nice if you take your time.) anyways, i used a poly adhesive backing used for neck collars in shirts and made a set of abs that way that i really liked but they still didnt feel right and i kept feling like they heat pressed the abs. i went ahead and made a die set and decide to do some testing and the photos are below. i believe its finally the look i was going for and wanted. My plan is im going to have a buddy cnc a female and male die set i can use to make them accurately because the set i made was with plywood and a jig saw.. not bad for what it is but mdf computer cut will tighten everything up and give me some great looking pieces
    Last edited by PerilloMarc; 1 Week Ago at 2:09 PM. Reason: grammer
  3. PerilloMarc's Avatar
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    1 Week Ago  Nov 29, 2017, 12:07 PM - Re: Captain America Civil War Build Process techniques fabrication #3

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  4. PerilloMarc's Avatar
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    1 Week Ago  Dec 1, 2017, 2:02 PM - Re: Captain America Civil War Build Process techniques fabrication #4

    I made some more sample abdominal pieces using a polyester fabric for ultility bags (blue) and another using like a vinyl material but flipping it inside out so the rubbery side would face in and the fabric weaive side faces out (grey). I used the same die set with a cavity and core made from plywood. Clamped the fabric down between the dies and then used the steam from an iron to form the fabric. Because the fabric is synthetic, it stretches and formed and holds the shape of the die. When I used cotton or stretch fabric, I had to water down silicone glue and paint it on the back of the fabric and then use my heat gun to dry it once it was pressed down between the two mold dies. I've also found by controlling the iron temperature and steam that I'm able to stop the warping, creasing, and seams because of lack of relief area for the material. Also going too hot will burn or even melt the synthetics. Dialing the iron in just right allowed me perfect pulls with no warping. I'm experimenting with back filling the fabric embossed pieces with silicone and fabric stabilizers now to see what it looks like and to try an stop the reverse push in that happens if the abs are pushed in on themselves. I'll throw up some more photos tonight when I get home but these are the few I had in my phone.<br><br>

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    Last edited by PerilloMarc; 1 Week Ago at 2:15 PM. Reason: Grammar
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    1 Week Ago  Dec 1, 2017, 11:03 PM - Re: Captain America Civil War Build Process techniques fabrication #5

    Hey love what you're doing with the project! I'm thinking of doing one myself, so seeing you do the costume as well is super inspiring!

    Though, must ask, where did you get the template for the costume?
  6. PerilloMarc's Avatar
    Member Since
    Feb 2013
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    East Haven, Connecticut.. USA!
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    1 Week Ago  Dec 2, 2017, 9:06 AM - Re: Captain America Civil War Build Process techniques fabrication #6

    I made Some in the computer and some I used a tight shirt, marked a few places on myself and drew the suit onto it.. then cut up the shirt to get the pattern. I'll post the files I've made in the computer if it helps. I got the abs, star chest price and lower triangle done. It'll be later tonight though when I get to my computer. I'm working on a template for the shoulder rubber piece at the moment. It's an odd shape and then bent so I'm reverse engineering it a bit so when I sew it on it looks right
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    1 Week Ago  Dec 3, 2017, 1:09 PM - Re: Captain America Civil War Build Process techniques fabrication #7

    That would be helpful!
  8. RPF Premium Member
    Member Since
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    1 Week Ago  Dec 3, 2017, 2:45 PM - Re: Captain America Civil War Build Process techniques fabrication #8

    Just had to leap in and say i love your creative solutions and ingenuity! Can't wait to see more.

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