It's that time again...kiddie costume time! I love it. This year, Zachary and I agreed to choose a Mad Max-y, post-apocalyptic theme. I was really excited about the possibility because I love to spray paint random stuff to look like metal--the effect is magical! But then, Zachary wanted to recreate a specific character and he chose one with whom neither of us were familiar--an NCR (New California Republic) trooper from the Fallout universe. Much Google-ing ensued. And this was the final result:
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| Zachary as an NCR Trooper |
I used some of my favorite materials and even had many of the materials on hand (left over from previous Halloweens). Here are pattern pieces for the bullet-proof riot vest laid-out on an EVA foam floor tile. EVA foam is easily cut with an x-acto blade and can be shaped by hand with heat from a heat gun.
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| Patterns for LAPD riot gear laid-out on EVA foam. |
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| Finished LAPD riot gear vest, painted and distressed as if it's seen a lot of battles. |
The mask began with styrofoam and craft foam sheets.
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| Styrofoam for the center of the...I don't know....is it a respirator? I shaped it and then sealed it with multiple coats of epoxy resin and acrylic filler. |
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| Gas mask is taking shape. The blue is craft foam "Foamies" |
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| Gas mask. Zachary complained that the paint job didn't match the vest, so (later on) I repainted this with more rusty-black colors and lots of dust over the top. The speaker-thingy in the front was sooo hard to make. It is really frustrating to try and create machined-looking parts from flimsy materials like styrofoam! |
The helmet began with one of the few pieces that I bought ready-made--it is just not worth it, in my book, to try to craft something as round as the helmet--especially when costume helmets are so readily available and inexpensive. But, it was plain 'ole, shiny, army-man-green plastic when I started and I added distressing, dents, bullet marks, scarring, and dust. I also built-out the com-link and light/laser-sight. One of the best parts of the transformation, In my opinion, was the com-link, which I built from the bottom of a "Glories" tomato container. Do you see it, now? I filled the container-base with insulating foam to make it a bit more rigid, carved the back to conform to the curve of the helmet, and cut the top straight in order to combine it with the mount for the light/"laser sight".
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| Helmet/com-link. |
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| Distressing on the helmet. |
I melted areas of the plastic helmet with a burning match and then crammed the match against the surface to get good texture. And I added dents by heating the plastic and tooling it with a melon baller. Then I added "rust" with layers of orange, brown, silver, and black paints. There's a super-sheer coat of limestone paint over the top to imitate dust.
Zachary chose this costume largely because of the weapon. Always with the weapons! Anyway, given the political climate, we decided that it would be inappropriate and unadvisable to carry anything remotely realistic. After much Googling, we identified this AER9 Fallout3 Laser Rifle as a "safe" option.
I cut the frame from 1/4"hardboard and added bulk and detail with pink insulating board, EVA foam, craft foam, a piece of pipe insulation, assorted caps, bottles, plastic tubing, and random nuts, bolts, and other hardware. IMO, adding real hardware is the simplest and easiest way to add realism to faux-metal items.
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| Laser rifle during construction. |
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| Laser rifle after distressing and application of stone-finish spray paint. |
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| Finished AER9 Laser Rifle. (High tech, homemade, Rubbermaid-tote spray booth.) |
I made a duster coat (modified from a pattern for a girl's raincoat...shhhhhh...don't tell Zachary!) from remnant sand-colored twill and painted and distressed it. There's an NCR insignia on the back and on the sleeve. And I bought an authentic army surplus tactical belt from eBay.
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| Sleeve logo on coat. |
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| NCR insignia on the back of the coat. |
Here's Zachary, all dressed up: