Picture of 1990 Shredder Costume
shredder first night.jpg
Shredder and Foot 2.jpg
Halloweens come and gone and here are some pictures of the shredder costume that I made this year.

This was my First time making a costume that used  pepakura, resins and Bondo Auto filler.

Pepakura file - Shredder Helmet
Pepakura file - shredder blade
X Acto knife / Craft Blade
Hot glue gun / glue sticks
Card stock
Disposable brushes
Aluminum pie pans for mixing resin and auto filler
Fiberglass resin
Fiberglass cloth
Bondo Auto Filler
Rubber filler spreader
Non slick cupboard liners
Small plastic grid
Card Stock
Dense poster board
Red glittery Fabric (jumpsuit/tunic)
Packing foam
Tabi boots
black fabric (sash/cape)
spray paints, (primer, black, silver)

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Step 1: Shredder Helmet

Picture of Shredder Helmet
shredder helmet.jpg
1)First thing you are going to need is a pepakura file viewer, if you search online it can be found easily and is free
2)Next you will need to search online for a shredder helmet pepakura file, It took me awhile, but I ended up finding one at www.theprf.com
3) load the file onto the file view program and print the file out onto Card stock.
4) Once you have all the pages printed use an X acto knife to cut out all the pieces.

Step 2: Helmet and mask assembly

Picture of Helmet and mask assembly
step 1-4.jpg
Now you should have all the pieces cut out and ready for assembly.
all of the shape that you cut out tabs on them, those tabs will be folded and glued with a hot glue gun and attached to a corresponding piece.

Step 3: Resin and fiber glassing

Picture of Resin and fiber glassing
step 2.jpg
steps 3.jpg
step 3.jpg
step 3-1.jpg
step 3-2.jpg
(1) Apply resin with a disposable brush to outside of the pieces and let dry, once dry repeat. You will want to get a few good coats on the outside
(2) Spray adhesive to inside of all the pieces and apply fiberglass cloth.
(3) Apply resin with disposable brush over fiberglass cloth.
(4) Once this all dries sand all sharp areas and corners so they are smooth

Step 4: Bondo & Sandpaper

Picture of Bondo & Sandpaper
step 5.jpg
step 5-2.jpg
step 5-1.jpg
(1)Mix and Apply layers of bondo filler using rubber spatula to the outside of the pieces and let dry.
(2) Sand with 80 grit sand paper and use dremel around edges and corners.
(3) re apply small amounts of filler into gaps and sand.
ChrisS58 months ago

How did you attach the helmet blade to the helmet itself?

brockerville10 months ago

Great job on this! I was wondering if you might still have the pep files kicking around, they're no longer available on any of the links at the RPF :(

smacias11 year ago
Question, did you bondo the inside of the arm and leg guards?
R2E2 (author)  smacias11 year ago
Thank you for your question smacias1, I used only resin and fiberglass cloth on the inside of the leg and arm guards.
poofrabbit2 years ago
Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!
R2E2 (author)  poofrabbit2 years ago
Whoo! Thank you Poofrabbit, I'm soo excited! Thank You! =)
csteiner12 years ago
So Rad
R2E2 (author)  csteiner12 years ago
That is amazing! I love it, just all of it is awesome!
R2E2 (author)  Penolopy Bulnick2 years ago
Thank you! :)