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Not sure where to post this in the forum list, but seeing as how I've found other posts relating to costuming here, here it is. Admins, feel free to move it or tell me where it goes....not where to put it, it's a big costume and that could potentially hurt.

Using a blend of Pepakura files and scratch built templates I have come up with this. Using foam kid's play mats and a hot glue gun is giving me an awesome base to work on. Much easier than fiberglass and i've been able to do it at work. Saves me a ton of time.




upper thigh




any crits are welcome...

because of this project my skaven have taken a backseat....ugh,,,,someone needs to find a way to fit 40 hours into 24....

If you get some convincing embellishments on that suit and it's all proportional then jeez will that be awesome, cool start!!

wow- that's awesome so far

Nice! Going to be a lot of work tho.

awesome job, I think I speek for eveyone when I say I demand templates

Very impressed!

The fact that it is going to be very light but still look solid and with that nice texturing is awesome, can't wait to see hoe it turns out!

That's already looking considerably better than most of the marine costumes I've seen. Cheers!

Exalted!

Wow... It would so cool to see a grey knight walk into the Games Workshop XD

That looks pretty damn good mate. Il be watching this thread.

Awesome!
I was thinking of doing the same thing, please keep this updated!

Very cool. Are you going to skin the material in anything afterwards before painting?

I've seen a whole lot of amazing things done with Plastidip and Latex as a skinning tool over foams. They take acrylic paints very well...

Ok that is amazing. I also would love to see some templates. I can't wait to see how this turns out.

This thread is going places! I love it.

Whoa, this is looking awesome already. Im so jealous man. You must finish this. This also is giving me ideas for my own costume.

**** UPDATE TIME AGAIN ****

since I can't use my glue gun at work anymore ( something about a Health and Safety violation...i dunno) , I figured I'd try skinning the helmet and arm pieces.

After doing a lot of tests and melting a lot of foam scrap foam pieces, (my wife is still pretty upset about the accidental damage to the kitchen table....) I came up with the following.



the helmet after skinning layer 1 --



the skinning material and implement of destruction. DAP Acrylic Painter's Caulk. works like butter. And my bank card to smooth it all out. It's useless at keeping my money safe from my compulsive hobbyism, so it might as well be useful for something.

Plan after this is to spray the entire thing in rockerguard -- a rubberized spray you can get in the automotive section at most hardware stores. Here in Canada we refer to this place as the wonderland that is Canadian Tire....it will hide the imperfections of the caulking, and give the ancient mottled texture that GK armour should have.

Why not just skin with a layer of rockerguard in the first place, you ask? Well, when it sprays on it looks great, after it dries, you realize it just soaks into the foam and really doesn't give the texture you want. The caulking acts as a sealer and in my tests came out as the clear winner....mostly for speed....

I had a test piece using polyurethane-- 2 coats made the surface smooth like glass....alternate for those who don't want a texture to their armour.

** On a side note -- Thanks for all the positive feedback..... my wife has been kind of surprised that my perfectionist nature hasn't kicked in yet, and caused me to scrap the whole project....all in all, I'm really happy with the build so far. And I'm only 2 weeks into it. 7 months until the Animaritimes Con in Moncton, New Brunswick, Canada. Canada Day Weekend... for anyone wanting to come up and join us.