Borderlands 2 Zero Costume

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Twitch8965

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Hey everyone!
I recently started to work on a Borderlands 2 Zero costume.
The ultimate goal of this project is to make a head to toe body suit, helmet, and a replica of the sword he uses.
Hopefully if the sculpt turns out well, I will do several casts and will sell them if anyone is interested. but before i get ahead of myself, Ill show you what Ive got so far!

this is to give you an idea if you dont know the character.
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I found these two images floating on the internet, no idea who made them, but if you know tell me so I can credit them!
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So, I started by printing out and measuring up some stencils, which I would eventually transfer onto some MDF board.
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I then measured cuts in each cutout to slip each piece into each other and made a sort of skeleton. then glued it together.
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Soon after I cut some pieces of insulation foam to fill in the negative spaces.
I cut curved pieces, but I realized shortly after that just cutting block pieces would have made fitting them in easier.
I glued them in using Gorilla Glue wood glue.
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NOTE! Ive read that using Liquid Nails would be a more reliable choice, but I have had no issue so far with the glue I used.
After the glue dried, I began to sand down the blocky shape into what would be closer to the final shape.
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Shortly after getting it as close to the shape, at least the shape that pleased me enough to continue, I began to seal the foam with just acrylic paint. Reason is Bondo and clay seems to have a difficult time sticking to the foam. Sealing up the foam with acrylic makes that much easier!
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Thats where I am now!
Ill be sure to update as soon as I have other pieces going!

ALSO, I will be starting up a blog page on my own site which I will provide I link to as soon as it is all set! Itll have other projects Ive worked on/will be working on so please take a look!
 
The helmet's looking good so far! If all else fails, I think I remember seeing a pep for Zero's helmet on the web somewhere...
 
Yeah I just recently found out there was one. I much rather have started with the pep file, but this method is new to me and is pretty fun so far!
But your right, if all else fails I got that!
 
Nice work so far! I'm making my own helmet out of EVA foam and PETG (for the visor). I used the pep file ender mentioned as templates. I hope your helmet turns out well, if it does, I might buy a cast.
 
Interesting way to build a helmet. Mind if I follow?
I just started playing borderlands. Tis FUN.
 
of course i dont mind! and feel free to ask anything about the process. I must warn im a fulltime student, so ill get back to you as soon as I can, but Im not on as often as id like.
but PLEASE I love to help any way I can!
 
That's looking pretty good! I used a pep file for my helmet, mainly because I'm too lazy to sculpt my own form.
 
I dont blame you, sculpting it from scratch has been a serious undertaking. Its paying off now though!
Feel free to share any progress with your helmet, Id love to see it
 
I've actually got my own thread goin on with my progress, go ahead and check it out if you're interested. :)
 
Very interesting method of doing a helmet. I' think I'll stick around just to see how this comes out. +1 sub.
 
Taking a break from the helmet a bit while i wait for supplies to show up, I started working on the body "armor" and the sword. I dont have much progress on the body other than I bought a leather jacket to modify a bit with a little help from a few fashion designers from my school.
The sword however, Ill be posting shots hopefully through this week, starting with this one.

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Not a whole lot of progress yet, just laying out and measuring the cuts. I found a person online who made their own Zero sword this way. I had to scale it down quit a bit because Zero is ridiculously tall.
The idea here is that Im doing to be cutting the blade out of this clear blue acrylic plastic sheet, and the housing for the blade out of another piece of acrylic. to make it glow, I bought an EL wire to run behind the clear blue to help make it glow.
By the time that the EL wire shows up, I should have the sword ready to be fully assembled and painted/detailed.
 
So unfortunately I havent had time to really work on this project, and when I had time, I ran into a few setbacks. The EL Wire I got ended up being no where near powerful enough to work the way I wanted.
For the helmet, I underestimated the amount of materials I needed. The good news is I got a resupply today so Im starting up the helmet again right now.

Even cooler news is I started getting my supplies of various leathers in, so I can start with the body suit.
Sorry I have no pictures of a more substantial l post about it, but I just wanted to apologize if anyone has been awaiting an update on this.
 
As long as you keep this thread alive I don't care how long it takes you. The thought of seeing a finished zero costume sounds realy amazing.
 
I saw that pic of the sword and was like YOU SHOULD USE EL WIRE WITH IT! Then read further down and saw you are going to, hehehe.
It will look great, will def be following this with much interest
 
You know, out of all the zer0 swords I have seen, everyone has been sucessful with LED strips, it glows MUCH brighter and its easier to work with.
 
If this is for halo-ween I'm disappointed. What happened to a spartan? Haha, anyhoo great build so far!

-PHIL
 
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