ODST Foam build - Stepping up from DFT

Discussion in 'Halo Costumes and Armor' started by Elcorio, Jul 20, 2018.

  1. Elcorio

    Elcorio Member

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    Not much progress thus far. Boot covers are giving some issues and I don't quite like the way they are coming out, so back to the drawing board.

    Cast a skull and cut out the flames in foam. Thinking I might add it to the center chest piece. Teeth or no teeth? Of course they will need some more work with paint, etc.
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  2. PaiganBoi

    PaiganBoi Sr Member

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    I like the no teeth.
    Looks closer to the ODST emblem.
     
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  3. Elcorio

    Elcorio Member

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    Alright there folks, 2nd forearm is complete, butt plate and cod piece are done! Last stop is the helmet. Actual build is nearing the end, then its on to filling in small gaps, smoothing out hard lines, then seal and paint! Nylon webbing and elastic webbing is on order for strapping it all together. Still have a bit to go, but slowly and surely, it'll get there.
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  4. Sean Anwalt

    Sean Anwalt RCO 405th Regiment Officer

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    Wow, that looks really good! I'm impressed with how sharp your details are.
     
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  5. PaiganBoi

    PaiganBoi Sr Member

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    How in the world did you get your cuts so clean??? :eek::eek::eek::eek::eek:
     
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  6. Begocer

    Begocer Member

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    By filling in small gaps do you mean just straight to painting? As those are some snug lines, yo! Great work!
     
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  7. Elcorio

    Elcorio Member

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    Thanks. I want to knock down some of the hard seam lines and fill in a few small areas were the foam pieces might not have closed completely or had gaps.

    I've also have never been to a con and today our local library held a small one. Suited up my youngest in his DFT armor. Had a blast and going to start planning for the bigger one in New Orleans next year.
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    Last edited: Sep 23, 2018
  8. Elcorio

    Elcorio Member

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    Started sealing the foam using Mod Podge. Shooting for 9-10 total coats per piece. These are at 5-6 coats. Between every two coats of Mod Podge, I lightly sand the edges which is resulting in baby butt smooth seam lines. Then it will be wet sanding with 400 grit wet/dry sandpaper over the whole piece before primer and paint go on. Hopefully, when done, the seam lines will be little more than distant memories. Also order 3 more full sheets (48" X 72") of the XLPE foam in 3/8" and 1/4". That is out for delivery today and will give me enough to build anything else for a very long time and to work on the ODST helmet counting mess ups. AND finally, started working on the inner portions of the thighs pieces. Sizing was a bit off as each piece needs to be slightly longer than the one below it, so it will be back to the drawing board, but I need to get some more 5mm foam. The inner pieces were done freehand, but I need to adjust the sizing for the three pieces in a step up type pattern.

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  9. Elcorio

    Elcorio Member

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    Trying to seal so many pieces all at once became a daunting task, so I decided to just work on one piece from start to finish. Also bought a beginners airbrush kit and thought I'd give the whole airbrushing thing a go.

    Pretty pleased with the results so far.
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    Last edited: Oct 15, 2018
  10. Dirtdives

    Dirtdives Keeper of Con Lists Community Staff

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    That chest piece is amazing!!!!! I may be good at etching in foam but that is a true emblem......I have to try your method out!!!
     
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  11. pipninja

    pipninja Active Member

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    How did you get the square texture in the paint? That looks awesome!
     
  12. Begocer

    Begocer Member

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    The smoothness is giving me serious fondant vibes...what flavour is it?

    ...Don't judge me.

    Can't wait to see how the rest turns outt!
     
  13. Elcorio

    Elcorio Member

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    If you look in the background of the picture, you can see apiece of the material I used. It is nothing more than the non-stick, rubber type shelf protector stuff you can pick up for a couple of dollars in the household goods section at Wal-Mart or the like. I botched it up quite a bit on this piece, but was going for a carbon fiber type skin. However, this was literally the first time I have ever used an airbrush. I keep looking at the piece and on the fence of pulling the emblem off, repainting the piece, and trying again.

    for an update on the build, the shoulder pieces and butt plate are sealed and need to be wet sanded and then paint. Those will be the next items up for paint.

    As a side note: Thanks for all the input guys and gals!
     
  14. Elcorio

    Elcorio Member

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    Oh man, why didn't I pull the trigger on an airbrush set up earlier!!! Shoulders and butt plate are painted. Still need to weather it and all. Picture makes the blue look purple, but it is actually called Ultra Deep Blue.
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  15. xXDashIVXx

    xXDashIVXx Active Member

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    ba ba ba ba ba, IM LOVING IT!!!!!!!!!!!
     
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  16. Lieutenant Jaku

    Lieutenant Jaku Well-Known Member

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    its so clean!!!
    whats your secret?
     
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  17. Elcorio

    Elcorio Member

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    Thank you. It's nothing more than repeated coats of mod podge then wet sanding the first couple of layers to smoothness. Of course, it all starts with your cuts, bevels, and making sure the two pieces line up as perfect as possible to avoid any gaps or open seam lines.

    I weathered up one of the shoulder pieces and am kind of "meh" to it. In all the excitement of using an airbrush, I forgot to lay down a silver base coat with a barrier for creating a chipped paint look in certain areas.

    Unfortunately, I have run into a major fit issue with the forearms and a fit assumption of the thigh and shin pieces. The BDU's I had planned to wear underneath are a bit loose and are not snug to the body. This creates "extra" material that was not accounted for in the sizing. Thus, theses pieces basically do not fit while wearing the BDU's. It was a bit of a bummer and initially destroyed my motivation to keep working on it. So I hung up the build for a couple of days to figure out the next step. I had considered starting all over, but that is a LOT of wasted time and effort. So I think I will look at each piece and see if I can created a clean slice on the underside down the entire length and insert a 3/4" - 1" piece of foam to allow for the added material of the BDU's. I think I am rushing it too much between the sizing and painting and need to slow it down a bit. I'll update as I make on the fly adjustments.
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  18. Elcorio

    Elcorio Member

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    As mentioned in an earlier post, I really didn't care for the botched carbon fiber effect and the ad hoc ODST emblem on the chest plate that was noobishly thrown on to quickly. Sooooo.........it all came off, sanded down, and a new coat of primer was applied.
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    From there, a barrier (AKA: Vaseline) was added and then hit with a silver paint. The idea was to give the piece some depth between the gray primer and the silver.
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    More Vaseline, then the straight black and blue were applied. A little bit of metallic saphire blue and sequin black dry brushing followed by some umber brown in the crevices to "dirty it up", then to a straight black wash to mute the silver and gray colors down a bit. That was then followed up with a umber brown wash to enhance the grime and wear and tear of battle. Lastly, a metallic gunmetal around the edging to highlight wear edges. I still am not comfortable with cutting or puncturing the piece to create an impacted look, but will practice that on some scraps first.

    I opted to not put the emblem back on the chest plate and am now looking into just creating an ODST stencil with cardstock, then airbrushing the emblem on. IMO, this seems like it would be better served on battle gear versus some big protruding emblem on the chest plate.

    Now I am finally happy with the way the paint scheme is coming along. Next up will be sealing, sanding, smoothing, and painting up the thigh and shin pieces. As a side note, the helmet is a dismal mess. After repeated tries with foam, I just cannot seem to master this and have opted to just save the foam (and money) and buy one from a reputable source.
     
    Last edited: Oct 26, 2018
  19. StarWolfStudios

    StarWolfStudios New Member

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    This looks great! All of the detail you've captured in the foam is mind-blowing!
     
  20. kyle clement

    kyle clement New Member

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    Hey Elcorio how did you attach the quick release buckle to the foam? I am looking to do the same and I was going to magnet my shins but the one I tried today didn't come out very good so I am thinking about putting the buckles on them as well
     
  21. Elcorio

    Elcorio Member

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    I think I have some pics of when I was building them into the foam. Essentially, I placed the buckle on the foam (1/2" foam), traced an outline, cut as much as I could with a blade, then dremeled the rest. Used contact cement to mount the buckle into the cavity I made in the foam then reinforced it with popsicle sticks on the interior of the foam piece. From there, I just covered it all with some 3mm foam for aesthetic purposes. I ended up cutting slits in the foam and use popsicles sticks hot glued in place to act as guides for the remainder of the pieces to be joined.

    I'll see if I can find the actual pics as I was building it and post them.
     
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  22. Elcorio

    Elcorio Member

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    So I was going to wait until I finished both pieces, buuuut...........the right thigh piece came out so much better than I had expected! Still trying to dial in the whole chipped paint look and it looks botched to me, but I'll just have to live with on this piece.
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  23. Elcorio

    Elcorio Member

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    Kyle clement, these are the only pics I could find. Thought I had more. Hope it helps.
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  24. kyle clement

    kyle clement New Member

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    Thank you elcorio. That is the part I was trying to make sure of was if it was attached to strapping or straight to form. I'm looking at going the same route and my attempt at magnets on my shin piece didn't come out very well so I may try these latches on the shin as well
     
  25. Elcorio

    Elcorio Member

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    Just to add a bit of build tips to the buckles. I also added a short piece of 3/4" nylon webbing folded in half where the strap would have gone for a helmet for added strength. Contact cement was used to secure it all and when I decided to go another route on the build, I literally had to cut everything out because the foam would tear if I tried to pull the buckles off.

    What kind of magnets are you using? The ones I used in the forearm are neodynium bar magnets and even using their small edge, they have unbelievable holding strength. I believe somewhere in the 33 Lb. area. If using the flat broad side, I believe the foam would rip before the magnets would give. In fact, the magnets come with a small plastic separator between them because you have to slide them apart. There is no way you can simply pull them apart. You have to slide them away from each other. If you are using the cheaper ceramic magnets, then yeah, I could see the lack of holding power.
     
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