Guild Wars 2 Charr build - Khan Grimblood

Terrible Trio

New Member
Hey all, my sister and and I are going to build the largest costume we have ever made.
We've been cosplaying for about 6 years, and usually run in group cosplays with out brothers - The Adventure Zone, the three protagonists of Dragon Age, or Overwatch. A few years ago my sister MJ and I did Marjory and Kasmeer from Guild wars 2 and we decided to revisit it in the most intense way. This was by creating the character she has run on for 5 years straight - Khan Grimblood.

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At the tips of his horns he will be 7"6, so for 5"11 girls it's going to be a large marionette with us inside controlling one arm and the head movement. It will involve .stl ripping, 3d modelling,. pepakura, PVC skeletons, metalworking, digistilts, articulated fingers, foamwork, claywork, painting, molding, casting and so much crying. He'll be large enough that when one of us gets tired of wearing him on a con floor we can swap out easily enough given that we are the same size.

To start I ripped Khan from the game using Ninjaripper. Quite the difference from the game screenshot!
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From here I removed the armor on Autodesk 3ds Max and cleaned up the sword. I then uploaded them to pepakura for additional dismantling.
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For scale, here's the hear and one of his hands printed. We assemble the pieces and then either break them back down for foam templates or use them as physical references for making PVC frames.

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I'll post the foam head and digistilts that we have completed in a little while, but we're making headway!
-K
 
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I patterned out foam pieces to craft the head, which we cut out and traced onto EVA.
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Here's the head basically assembled but unglued.
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And here it is with the ear work done, carving, and jaw hinges.
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We designed out our digistilts for Khan's legs and used thick sintra sheets as the supports, measured to fit both mine and my sister's legs. Here's them after our brother cut them out.
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After 14,000 washers and bolts, nylons strapping, and metal bars, we have functioning stilts! the feet bases just need to be welded onto their C-brackets to allow for swiveling of the foot.
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They are indeed as difficult to walk in as they look.
 
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We started mapping out some of his teeth! We'll transfer them to pink insulation foam later, but at the moment we just needed a visual for jaw placement.
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Look at that smile!!!


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Here's the current rig for his jaw. With the giant horns attached it forces the lower jaw to do the moving and keeps the upper part of his skull in place.

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love me some good GW2 costumes.

If you learn to do the Charr run, +10!

Not gonna use the charr backpack? Quaggan backpack?
 
Thanks you guys! We have the rib cage done with some delrin rods (stripped from a popup Ikea tent) for the neck for his head movement which I will post later.

love me some good GW2 costumes.

If you learn to do the Charr run, +10!

Not gonna use the charr backpack? Quaggan backpack?

No backpieces yet unfortunately, but that seems like a good idea. At the moment it's just detailed plate armors seen in the screenshot but that could be cool it it matched the wolf-skin mantle. His intricate prop will be the warrior's battle standard for raising downed players so we can keep our balance.
 
Here's the rib cage constructed out of pvc piping and support bar. there's a v-joint in the back to attach to a neck/trapeziums area of a vest we're making in order to keep the whole cage suspended.
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Here's a video of the neck movement in conjunction to the chest frame above. His neck is acetyl rods we pillaged from a pop-up Ikea tent.

 
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Hey guys, back in the workshop again! Had to take a siesta due to cat drama and illnesses, but in the meantime We mounted to head to the neck pipes using a worbla ball/socket and rope hinge. It's super steady and very flexible now. We've also mounted him to get better access to the bolt and nuts sticking out of him so we can cover those in padding. I also started shaping his upper and forearms, and I'll get them hooked on with leather, velcro, and more hinges. More pics to come soon!

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Great start, and I'm excited to see the results!

I have a few GW2 things underway, but not making amazing progress. Seeing this makes me want to dig back in.
 
Hey all, sorry for the content desert - we were swamped by convention competitions of guesting. Here's a video if a test we did earlier today after tweaking the stilts a bit.
 
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Woohoo, Khan has an assembled upper body! (granted, that assembly may be primarily tape). We are currently wrapping his chest cavity in chicken wire to give his fabric wraps something lightweight to stick to, and I'll have his fingers all connected to the control gauntlets in his elbows soon. I've cast his eyes (one working and one blind), and we're working on making some realistically flexible lips!
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We've done a lot of work in the last few weeks, it seemed it was time to update here.
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We furred up his face and neck, and coated his whole upper body and arms in red wrap and more fur. Hannah taped off his reverse-tiger pattern and airbrushed it all through. Here's what he looked like after those steps:

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His horns were constructed and painted, he received his jewelry and mane, and MJ scarred up his face.

I'll post more about his arms and legs later.
 
His legs are approaching completion. Since taking this picture I have attached the joints in his knees, wrapped the claws in worbla, and wrapped his legs in the same red fabric around his hands. We'll be able to attach fur and armor soon.
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Here's Khan with his arms and armor attached. This dry run showed us that the mechanisms in his right arm had snapped and his spine was loose, but he looked pretty cool otherwise!
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Okay, it's been a while since we updated. We've totally finished Khan, brought him to TwitchCon, and won best of category for Larger than Life, which we were super surprised about. But the last post had us in the middle of the legs so I'll start from there.

I covered his claws in worbla and hit feet in flurry black fur, and wrapped all the foam in red felt strapping.

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I connected the thigh pieces we crafted out of foam to the shins with some metal v-hinges so that there would be a swinging motion at the knee. The front of the knee was hollow to keep from fabric bunching, and the back of the knee was also cut out so we could stand straight. here's a diagram i made for someone who asked:
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After we got his legs working (they're held up by a weightlifting belt that has Velcro straps that attach to the inside of the thighs), we constructed his hip guard, belt, and thigh armor.
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The knee gap is covered by his armor so it's not noticeable, and with the red wraps your eyes gloss over the black pants you can see behind his knees. This gives the illusion of digilegs without having to strain your thighs. Here's how it all looked together after repainting and weathering:

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Next post I'll go over his tail.
 
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