Custom Sci Fi Armor Suit

[Ogunn]

Hey Peeps, been a while since I tried to make anything since the Boba Fett I did, which took forever and cost a lot since it was my first and I didnt know what I was doing. I have since taken that knowledge I gained from that build and decided to give it another go on a custom piece for myself with EVA foam from harbor freight.


So, I need to start with a proper mannequin so I can get my pieces to fit better without all the trial and error on myself.

I used some long sleeve spandex shirt and pants. Duct taped it all the way around my self. This is so when I cut it off it has my exact proportions when I re stuff it.

Uploaded with ImageShack.us

 

[Ogunn]

the suit cut off. almost like a piece of leather or something. Holds the shape. I cut from ankles to knees, wrists to elbows, neck to top of butt, and then you just slide out of it.

Now for the endoskeleton frame and stand. I used pvc pipe. need 6 90 degree angle connectors, 1 cross connector. 3 T connectors. Of course you want to measure the pieces before you cut so you know it will fit inside the duct tape suit.

Now put the pvc frame inside the duct tape suit, seal up the leg seams and start stuffing with old clothes or cotton or pillows, or whatever you have sealing up your seams as you go up to the neck. once done you can make the base with 4 90 degree and 2 T connectors and a measured length of pipe cut etc.

you glue all the pvc parts in the mannequin and the base, but DO NOT glue the base to the mannequin, that way you can take it off the base to change out suits for display...

 

[Ogunn]

Ok. Now that I have a proportionate mannequin, measuring out the pieces etc will be much easier. Now comes the fun part of coming up with the actual design of the costume. I spent a few days just doing rough sketches of stuff until I got a basic idea of what I was shooting for. Of course once you start making it, you have to adapt to whatever resources you have at your disposal, so it is gonna change a bit. The basic idea is solid though.


Tactical Suit

Skin Suit

More of a heavy armor with helmet type of space suit. Couple of different helmet designs. wasnt sure what I was going for.

Another with heavy armor to get an idea of what it would look like in practice. Also might as well add a well endowed female in there too

Finally. I settled on the heavier armor look. I decided to give him some predator like blades on the left gauntlet.
So this is the basic suit design I decided on.

 

[Ogunn]

Made the chest armor. has clips to connect the back which are hidden by armor plates on top. I am not doing any sanding on any of the armor until I have it all made. Then I will go back with my Dremell and sand all the rough edges and glue seams smooth so it doesnt look cheap or unfinished.

So it is now on the mannequin and I added a styrofoam head I already painted and detailed.

 

[Ogunn]

THE GAUNTLETS

took a bit but by adding enough shapes to them, I am pretty happy with the gauntlets.

left gauntlet

I made the blades from 2 plastic pie serving things that I cut with my dremel tool.

The finished left gauntlet.

Right Gauntlet
The green glowing fluid things are levelers for hanging pics or doing carpentry. I liked the color and they were only .60 cents a pop so i got a few to look like fuel gauges. Also, I added a functional Led light with 5 bulbs and several different settings including a strobe.

THIGH ARMOR:

THE SUIT SO FAR:

incidentally, I bought some ugz type boots from walmart for cheap. they were female, but I got them in size 12 which fits me perfectly. Then just a matter of painting the leopard print on them black with a few light coats of spray paint. I also had some rubber boots that were too small in the feet, but I cut the leg portion off and it looks pretty cool. slides over the top of boot. Also a pair of sports gloves that I painted black. I pretty much painted everything black just to give it a solid color. Im not planning on keeping it black.

 

[Ogunn]

Greebles, clips, straps, hoses etc.

Now its time to start on the helmet.

So I went to our local gun show and got an awesome military grade gas mask for $20 and a couple of really cheap toy plastic army helmets. I cut 1/3 off each helmet and then spliced them together.

I changed the color of the eye pieces to blue by cutting a piece of blue plastic notebook binder separator sheet and just sliding it behind the lense. it works but makes seeing a little foggy...gonna have to figure a better method out...or i might just keep them clear and get some El wire and make them glow from inside the helmet. I'll get back to that later....

 

[Ogunn]

my old xbox 360 had decided to destroy itself a while ago. Still had it around for some reason, so I cut off some parts of it with my Dremell tool to add to the helmet. The three round cartridge things near the ear area are from a Nerf toy gun shotgun. i guess the shells eject out of the toy gun after the nerf dart shoots from the tips. idk, I dont have the gun, I just got a couple of extra ammo packages for it on clearance at walmart. I used some on the gauntlets too to make them look like mini flame thrower nozzles....

The on/off button from the xbox on the side. gonna add an antenna and a couple wires too.

Also, keep in mind I am not doing any smoothing and sanding of edges until I have the whole suit made. The helmet is going to clean up very nice.

 

[Ogunn]

Ok, got a little update. Finished my lower leg/shin armor and boots. Also finished my helmet. Besides sanding of course. Will prob get to that next week.

 

[Bothan]

Very cool build to follow friend. Keep up the fantastic work. I can't wait to see how this suit turns out.

 

[Ogunn]

Thanks Bothan. The costumers here are tops, so getting respect from them is like, gold...or something....

I'm making templates of this as I go. For the basic suit anyways. I plan on making a few more so me and my buds can make some homemade sci fi short films for fun. Do some green screening...foley, etc. After seeing Mackazi One, I really wanted to do something kinda like that....so, if anyone has any tips, that would be great. I'm looking for a decent vid digital camera....around 500-800 bucks.....new....I'll make all my own dollys and grips and tripods and greenscreens...

Heres a vid for that if anyone has never seen it, It's an awesome fan made star wars film with lots of bobba fett armor....

 

[Ogunn]

I cut up an old flashlight radio with my dremel. Got lots of cool pieces from it to add to the helmet.

 

[Ogunn]

Started on a rifle today to take a break from the suit. This is just the basic design. lots of angles to be dremmeled down to make it look less square. Cut a handle off a spray bottle for the grip and trigger. Used a cardboard tube for the stock/frame/barrel shroud. Vacuum attachment for the barrel.

 

[Ogunn]

I'm back. Took a detour to make my camera equipment....made a crane/jib, a steady cam, and a shoulder mount....once that was done got back to the costume but didnt like the fit or look of the cuirass , so I redesigned one that fit snug and allowed for more movement....in the stomach area and arms....Got some rough paint schemes on it...gonna do some more weathering and stuff...finish the helmet and gauntlets...getting close....

 

[Necronaut]

Overall, it's looking pretty good! My only suggestions are to maybe bulk up the chest area around your pec/shoulder (it's got a pretty deep cut-in you may want to camouflage with maybe a pectoral plate over top of it) and uh... "enlarge" the codpiece? It kinda looks like a banana hammock in the last pic.

 

[xanthis02]

costume A nutbar in said costume B

 

[Ogunn]

LOL!!! yea, the cutouts are deep in the chest so I can have full movement of my arms. That undersuit isnt what Im going to use, it's a cheap 5 dollar painters one piece and very thin material. I have a real flightsuit Im gonna wear under it. What I planned was making a couple of small crescent moon shaped pieces that Im going to attach to the flight suit between the chest and arms with velcro that will move with the material when I move my arms and be able to kinda collapse into itself so I dont sacrifice movement. I'm shooting a film with it so I want it to be fluid and practical.

As for the codpiece, lolz, I need to stuff the mannequin a little more apparently it doesnt fit properly. That small piece actually is like the...uhhh....taint cover...I had to make it thin so I dont have to stand bow legged and stuff....and I dont like the idea of one that ends right at the front in case I fall on it or something slams into it when Im wearing it, I dont want it able to smash into my beans an frank lol. there is a wider less banana hammock looking piece kinda covered by the ammo pouches I had to pull it up a little higher to take the pic because I dont have all those pouches above it strapped in properly yet. Also, Im gonna have some straps connecting the thigh and codpiece (as well as the gauntlets and biceps and those to the chest. all with clips to disconnect. I already cleaned out my local stores of that and they need to restock first lol) which is gonna add some more detail to those areas and make them less conspicuous....well...hopefully

 

[PunisherFett]

HOLY COW!!!! Awesome build .

 

[T90]

Wow! Your ability to turn an imagined object into something tangible is quite impressive. The suit looks fantastic. Good work.

 

[Ogunn]

Thanks guys.

Also, forgot to mention, the backpack on the suit is actually the cardboard shock case to my digital camera. Y'know, the thing the camera goes in, has the cords separated and bagged up and then they slide it in the box...took a bit of sanding since its like the outside of a mold and isnt the smooth side....but I was looking for something to add detail to the backplate and found it and thought about the stormtroopers little backpack kinda thing they have and I was like yes!! Some knobs and other greebles and paint and it looks pretty cool I think.

 

[Necronaut]

Cool stuff!