![](https://s3images.coroflot.com/user_files/individual_files/378627_5wpznk2cf0qqihkscrxv0xgjg.jpg)
First step I took was figuring out the sizing and shape of the suit.
Here im using large sheets of bristol paper to make sort of a mock up of the armor
![](https://s3images.coroflot.com/user_files/individual_files/378627_lvmooqoe6qvcw9nbbbwymmdnf.jpg)
After trimming and resizing the chest plate to fit right, I traced it out on a mat of EVA foam.
![](https://s3images.coroflot.com/user_files/individual_files/378627_ob5uw9maw_eklxijzh6aksieq.jpg)
When making the suit I felt that this material was the best to work with because its light weight, easy to come by and afford, AND easy to shape. You can take a heat gun to it and form it directly to your body to get accurate shapes.
![](https://s3images.coroflot.com/user_files/individual_files/378627_ghbtfedhu8knjaj0qrmizoqpm.jpg)
shot of all the pieces cut free
![](https://s3images.coroflot.com/user_files/individual_files/378627_85zorhfotqkb6lk6xbjysoene.jpg)
Next I used a hot glue gun to attach all the pieces together, and i began mapping out with a marker where the next, more detailed, layers were going to go
![](https://s3images.coroflot.com/user_files/individual_files/378627_raoww0sqmewfincrknkfijvww.jpg)
With the help of my sister, I got to see how well it matched up to my size.
![](https://s3images.coroflot.com/user_files/individual_files/378627_nzvadhemwjj8pxwy_ph9acway.jpg)
Next I began "roughing" out what the back plate and shoulders would be like.
All of this would basically be covered up by the detailed foam layers and paint, so I felt it was alright to me a little messy with this layer.
![](https://s3images.coroflot.com/user_files/individual_files/378627_xb2wpvwv3qyl_s2sgrm_ooadi.jpg)
Then I began to start adding a second foam layer to what I had to bulk it up and give it a better shape.
![](https://s3images.coroflot.com/user_files/individual_files/378627_ve8u6ebplysfmzgeutfc_7idy.jpg)
Another shot of the next layer
![](https://s3images.coroflot.com/user_files/individual_files/378627_ax5amnzdzl0z0_i9crqthppcn.jpg)
Next a used a super thin foam called "Foamies", also very inexpensive and easy to come by. this helped a lot with the thin details like on the circle bits.
![](https://s3images.coroflot.com/user_files/individual_files/378627_d2vr5bzq2j5dejfegm0a480ol.jpg)
Next I began to weather it a bit. Usually I take it easy on the weathering on props and stuff, but I decided to really go at it on this suit since it was supposed to be very war torn.
![](https://s3images.coroflot.com/user_files/individual_files/378627_ilcmhnm6ezhusiyycf4uctvoz.jpg)
Next up I coated it with a rubber spray called "plastidip" which you can find at home depot and other hardware stores. This helped seal the foams "pours" so it could take paint much easier.
![](https://s3images.coroflot.com/user_files/individual_files/378627_dk3mknphd73544evp0xipsfqh.jpg)
After spending a few hours with various spray paints, acrylic paints, and inks I managed to get the colors in a place I was very satisfied with. If I had more time to complete the suit, I would have wired lights through the suit. But I had finished the paint job literally hours before the convention.
For the weathering it was various methods of burning the foam with the heat gun, skidding across the surface with a dremel, cutting at it with a box cutter, and digging chunks out for the gouge marks
![](https://s3images.coroflot.com/user_files/individual_files/378627_rmdqcamoyipvnyrfr2fzy5dmx.jpg)
A shot of the back
![](https://s3images.coroflot.com/user_files/individual_files/378627_yrp6ohkxzugogsigomgdbcke0.jpg)
I handled he boots in the same fashion. Work out all of the sizing and designs and traced it out onto a foam sheet.
![](https://s3images.coroflot.com/user_files/individual_files/378627_qwhoeytxyvu9bxl3qsfnorrgt.jpg)
Here we can see the basic form of the boots
![](https://s3images.coroflot.com/user_files/individual_files/378627_jpj6jupvv_qj9sj8kwj4c4fxi.jpg)
Several layers of foam and cutting and sanding, I coated it in platidip.
![](https://s3images.coroflot.com/user_files/individual_files/378627_smbqyx79tufy4ckafioeyxjxp.jpg)
Here I started with the painting. Dry brush Hammered silver paint and added a bit of ink to settle in the cracks.
It was REALLY hard to bring myself to continue painting this because they looked so cool like this.
![](https://s3images.coroflot.com/user_files/individual_files/378627_jya0hk0eg873ojaxhcwfwwdme.jpg)
Here they are finished with all the paints and such applied.
I fashioned a cheap knock off croc in the bottom of the boot to fit comfortably, as well as a hinge in the ankle to move with my foot.
![](https://s3images.coroflot.com/user_files/individual_files/378627_svrmcuev7wretqpfpmumjxuu7.jpg)
Here are all the pieces placed out. I dont have write ups for the leg guards, arms, or the belt because its the same process. The gun was bought and I take no credit for. However, Id love to make one for myself.
![](https://s3images.coroflot.com/user_files/individual_files/378627_mvq9gbhmidmihrzx5dwfvmpgn.jpg)
A photo taken by my friend of the final product
![](https://s3images.coroflot.com/user_files/individual_files/378627_x8ss9fgyfsqeo6b3ync_k3sqv.jpg)
A photo with one of my friends. I didnt make her costume if you were wondering
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