New Recruit, ODST Cosplay WIP (PICS)

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chase314

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Hello everyone. My name is Chase and I've been frequenting the 405th for a long time, but never had a reason to post. After getting into Cosplay a couple of years ago, I decided to tackle an ODST costume. I have been working on this off and on since late last year, and will be wearing it to DragonCon next month! I took quite a few photos, so I will be posting those here. I will be making postings chronologically. I'll be posting updates over time, so stay tuned!

It all started with a helmet from Branfuhr Studios and a box of armor from Sean Bradley...oh and lots of reference photos.

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Tony stark built this thing in a cave! With a box of scraps!
 
The first step was to trim and sand excess resin, as well as remove the solid visor. I drilled pilot holes before attacking the visor with a dremel tool.
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My buddy Karl is doing his own Dredd costume, you'll see him in a lot of my posts helping me out :) Who would win in a fight: A generic ODST or a generic Judge?
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The first step was to trim and sand excess resin, as well as remove the solid visor. I drilled pilot holes before attacking the visor with a dremel tool.
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My buddy Karl is doing his own Dredd costume, you'll see him in a lot of my posts helping me out :) Who would win in a fight: A generic ODST or a generic Judge?
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Can you link me where you found the helmet and the suit of armor? I'm attempting to have mine ready before wizard world this year. Good luck! :)
 
Can you link me where you found the helmet and the suit of armor? I'm attempting to have mine ready before wizard world this year. Good luck! :)

Hello! I got my armor kit, knife, helmet and backpack from Sean Bradley. He's pretty famous on here, but I ended up just finding him on facebook (his profile pic is a blue man). FYI, he recently moved, so might be backlogged.

I got my gun kits (not yet posted) from https://www.etsy.com/shop/BranfuhrStudios. Good luck on your cosplay!!
 
After removing the visor, there was quite a bit of sanding and smoothing to do. I test fitted a visor, and noticed that I had gotten a little uneven with some of the edges which was causing gapping around the edge, so we constructed a shelf out of plastic and bondo to help fill in that gap. Final picture is after priming the helmet with said plastic piece in place.
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The next task on my list was to backfill all of the armor plates with Smooth on two part epoxy resin. After taking an inventory of the parts, we scuffed the insides of the armor plates, then we cleaned them out with rubbing alcohol. Last picture is my buddy Karl demonstrating the casualties of back filling, we went through an entire box of chip brushes.
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After back-filling all of the armor plates, the next step is to trim the excess plastic and flashing from the armor pieces. My friends Karl and Rob came over and we had a belt sander & dremel party. Wear respirators to protect your lungs kids!
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After back-filling and trimming the armor it was time for....the shining! Wear eye protection kids! We taped the pieces together, then drilled pilot holes. After the holes were drilled, we used a hand rivet gun to rivet all of the pieces together. Sean Bradley provided pretty detailed instructions.

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Next step: Rivet the gauntlets together. We taped them, drilled pilot holes, and more rivets. In the end, I didn't know what to do with my hands :p Oh, and then I got engaged to my lovely fiancee. I hid the ring in the garage so she wouldn't find it.
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Riveted together more of the large pieces, including the back plates and the chest plates.
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Next Step: Shoulder Armor. At first, planned on making a form out of heavy vinyl material for the shoulder armor to attach to. I was later tipped off that there are some kneepads from Lowes that are pretty much perfect for that task....so now I have a much better solution. Plus, I have a cool headdress :p Last picture is the tactical vest that I plan to wear under the armor for some of the different pieces to attach to on manny the mannequin.
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Thanks everyone for the kind messages! I have a lot more photos to upload (the armor will be done in the next week or so), I just need to sit down and upload the rest of them :)
 
The next step was to use nylon to attach the different parts of the armor together, including the front to back neck pieces. I used a combination of Nylon with parachute buckles and velcro. I then riveted the connecting nylon onto the toe caps and put a piece of foam in the cap to create an offset. Next step: Priming the shins, toes and thighs! Sorry for the huge photos, I was toying with different size options. What do you guys prefer? This was "medium" size. The previous photos have all been thumbnails.
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Photos during this phase start to get a little spotty, as we go into overdrive. I was looking for some specific Duplicolor paints, and all of the nearby stores primarily sell Rustoleum or Krylon! Autozone carried some of paint, but in very limited quantities, so I ended up buying most of it on Amazon. Some pics of me test fitting the chest plate, caressing Manny (don't ask) and priming all of the armor plates.
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After priming all of the pieces with grey primer, we painted them with Duplicolor gunmetal (matches GM). After multiple coats of the gunmetal, I used a dry brushing technique on the parts to give them a more scratched/worn look. By the way, if there are any questions on a specific part of the project, or the techniques used, please feel free to ask and I will go into more depth. Just giving an overview of the process.

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Now time for the helmet! I chose green (my favorite color) as the accent color for this armor. I chose to use a resist method for the weathering on these portions of the armor, so I laid down a layer of primer, then brushed nickel, then a resist (toothpaste) then green/gun metal over the resist, that allowed me to wipe the toothpaste away and have the nickel show through. I had to even out the transition between paint types with a very low gauge
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I proceeded to paint the chest and back plate gunmetal, after removing and sorting any nylon that I didn't want to have to mask off. I then took the thighs and gauntlets and used different shades of grey and anodized bronze to get the camouflaged look.


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I decided to add some green detail to the shoulder pauldrons, and the masking on this part was a pain. Things are starting to come together on Manny.

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