Roberts Space Industries
Submitted 2 years ago
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Kinshadow’s 2016 CitizenCon Cosplay Build

Hey Cits and Civs, this is Kinshadow. You may know me from the random stuff I do in the community like the Guard Frequency Podcast (http://guardfrequency.com), my card games (http://kinshadow.com/games), my pumpkins, my Valentine’s day cards, etc. If you happen to be an OG Star Citizen fan, you may also know me as that guy who used to dress up like a pirate and hunt Logante on Wingman’s Hangar. For this year’s CitizenCon, I decided I wanted to dress up like my old pirate self once more, but the old shiny trenchcoat just wasn’t going to cut it (it smells like mothballs and plastic). I had some time on my hands and I figured I could probably pull off some half-way decent cosplay if I put my mind to it. You can see the results below in the first two pics.

Since then, a bunch of people have asked me ‘how’ I built my helmet. So, I decided to make a howto post. Before I start, I’d like to point people to a great couple of resources for EVA foam crafting:
- My original helmet and shoulder templates from from Evil Ted Smith : http://eviltedsmith.com He sells foam templates for a reasonable price or shows you how to make your own (which I do in this post). He also has GREAT videos on how to build all sorts of costumes.
- Humble Bundle just happens to be doing a cosplay foam crafting book sell!
https://www.humblebundle.com/books/cosplay-book-bundle
- I scanned all the templates I used in this build. Feel free to use them and skip about half the steps in this build :D You can download them here:
https://drive.google.com/file/d/0Bwet7KWDw9emWGJuTHRWZDdoWmM/view?usp=sharing

Make sure you mouse-over each pic to see the text instructions

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Here’s a Cellphone pic of the costume front and back

Here are much nicer pics done by https://twitter.com/shewmonphoto

I decided that I should start off using a template so I wasn’t starting from ground-zero. I bought the Evil Ted basic Big Helmet template and cut it out of half-inch foam mats.

The template is simple, but it took me a couple tries to get the heating and gluing technique down right. Again, watch the Evil Ted helmet videos to get this part.

After some experimentation, I found that I really needed an armature for the face portion of the mask. Something to hold everything together while I figured out the pattern. Also, I needed a solution for the eyes since leaving them open wasn’t really an option. I ended up getting a airsoft mask off Amazon for ~$15. I then cut down my helmet to make the mask mate to it and glued them together.

I then covered the mask in aluminum foil and duct tape so I could sketch out the foam template I needed to make. I looked at in-game screenshots and went through a couple iterations lightly in ballpoint pen.

I then went back over the final pen marks in sharpy and colored it it with notes on thickness. And overlaps.

I only did half the helmet as I just needed to cut most of the patterns twice for both sides or simply reverse them to get the mirrored image

I then cut the wrap off the helmet and cut the patterned pieces out to create shapes. Where needed, I cut slits to flatten the pieces out. Again, Evil Ted talks about this process in his videos.

After cutting them out of the tape, I then transferred them to paper. I scanned these in so I could make copies without screwing up and you can download them here: https://drive.google.com/file/d/0Bwet7KWDw9emWGJuTHRWZDdoWmM/view?usp=sharing

I then took the templates I generated and cut them out foam. For most pieces I tried both 5mm and 3mm foam so I could play with the thickness. Only the back 2 grills ended up being half-inch foam.

I then took all the pieces I made and taped them to the helmet to make sure I didn’t screw anything up in the process. This is also where I finalized the thickness I was going to use. I didn’t document which one I picked, but you can see them in the images.

For the grill, I took a rectangular half-inch piece and used a dremmel tool to make grooves in it similar to the game grill

This is the grill + nose piece added to the taped helmet before I glued everything on

Everything finally glued on

Everything finally glued on

I took two pipe insulation tubes and ran coat hangar wire through them and up into the foam of the helmet. I then covered each tube with some wiring tube to get a more mechanical feel.

I masked off the eyes and the inside face mask and covered the whole helmet in around 6 layers of spray-on Plastidip to protect it.

After thorough drying, I then masked the plastidip where I wanted the mask to kept black and spray-painted it with Rustoleum dark metalic paint

After thorough drying, I then masked the plastidip where I wanted the mask to kept black and spray-painted it with Rustoleum dark metalic paint

I went back through with some model paint and hit some detail spots. Mostly red areas.

Lastly, I dabbed the whole thing with clear floor varnish to give it another protective coat and some gleam.

Lastly, I dabbed the whole thing with clear floor varnish to give it another protective coat and some gleam.

For the front armor, I took a rectangular pieces of 5mm foam, plastidipped them and glued them on a wind-breaker

I added velcro to the middle piece so I could still access the zipped of the windbreaker

The shoulder pads are pretty much just the Evil Ted pattern. I cut some overlapping rectangular pieces of 3mm foam to kind look like the helmet top and glued them on top.

The font coat clasps are 5mm shapes I hand draw, cut, and painted.

I put velcro pads on the back so I could attach a LED matrix array

I used a Badgerstick arduino board that I got free at SXSW. It came with a small LED Charlieplexed array. You can get the schematics for the array on their website and the whole thing is open sourced.

I used the Badgerstick array schematic to just make a bigger version of the array using bigger LEDs. It was a bit sloppy, but it worked :D

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