Years later I've developed a bit of skill collected some helpful tools that allow me to make some reasonably impressive costumes. I've taken on project after project, but no matter what else I've built, I've always found myself thinking back to those beloved characters from my youth.
After trying to talk myself out of it for years, I've finally accepted the fact that I must build Space Marines in all their glory or I would never be satisfied with any of my lesser projects. To do it right, the finished characters would have to be about eight feet tall and four feet wide. Given that requirement, the main challenge was to make all of the pieces lightweight enough to still be a wearable costume.
With that goal in mind, most of the components were vacuum-formed in thin sheet styrene or ABS plastic. Some of the more intricately detailed parts were sculpted in Magic Sculpt epoxy putty or molded and cast in urethane resin. The whole project ended up taking about three or four months worth of actual work spread out over about ten months worth of the calendar.
While I suppose I've got a bit of experience with this kind of project, I will admit that this tutorial is not the end-all-be-all resource for this sort of build. The intent is to inspire other people to take on similar projects. I encourage you to do more research and spend some time gathering additional references before you begin. I may have done everything the hard way.
It's also important to point out that Space Marines are the copyrighted intellectual property of Games Workshop and I have used the design without permission. I'm a fan and these suits are a tribute to a rich universe that I have always loved. This project is in no way endorsed by Games Workshop. Instead, I decided that there just wasn't enough Warhammer stuff walking around in the world, so I took it upon myself to help.
In describing this project I tried to be as brief as possible, but there's simply no way to describe all of the hours and days and weeks and months worth of work that went into this project in 50 words or less. Since it is a bit on the long side, I've at least tried to keep it entertaining. So pour yourself a beverage of your choice, get comfy, and let's begin...