Introduction: Captain America: Winter Soldier - Stealth Suit Build

Picture of Captain America: Winter Soldier - Stealth Suit Build

As Captain America has a different suit per movie, I'd created different costumes for myself. I'd already worn the Avengers Captain America Costume (mostly store bought), and my Super Soldier Captain America Costume (mostly custom) a few times each. So I decided I wanted to make a Stealth Suit Captain America Costume (nearly all custom) Similar to the one in the Winter Soldier movie.

Step 1: Research...

Picture of Research...

I always start with research. This helps me decide how to pursue a particular build, and even helps me to figure out what materials I may need. I often make a "style sheet", so I can view the proposed design from every angle (if possible). With this build, I decided that I wanted to reuse my Custom Helmet I'd already created for my Super Soldier suit (see my Instructable on building the helmet). Seeing as the graphics on the helmet were white (not silver like the movie), that meant I wanted my suit graphics to be white too. I did, however, prefer the graphics layout from the movie version over the comic version (the star with circle just seemed TOO oversized to me). With all that in mind, I knew this wouldn't be EITHER movie accurate or comics accurate, but a combination of BOTH.

I should also mention that I'd be reusing my customized shield too (I'll do an Instructable on this if needed).

Step 2: Materials...

Picture of Materials...

I thought a good base for this suit would be a navy blue flight suit, so I started there and added the other pieces as needed...

  1. Navy Blue Flight Suit (ordered off of
  2. Brown Leather Gloves (Under Armor Badge was removed, ALSO reused from Super Soldier suit)
  3. Palladium Brown Leather High Top Boots (They have a military look to them, but are QUITE comfortable)
  4. Skateboard Pad Set (Specifically wanted black and blue)
  5. Knee Pads (Wanted them simple)
  6. Soccer Shin Guards (Will use them as forearm guards)
  7. Various Buckles and Clips (Fashion Belt Buckle, Plastic Clips, Carabiners, Quck Links, Overall Clips)
  8. Black Nylon Belting/Webbing (Used for straps and etc)
  9. White Craft Foam (Used for chest and shoulder graphics)
  10. American Flag and SHIELD Patches (Military grade for shoulders)
  11. Blue Automotive Spray Paint (For knee pads, elbow pads, forearm guards)
  12. Loctite for Vinyl (to adhere craft foam to chest piece)
  13. Fabri-Tac Glue (to adhere any items that aren't sewn or stitched down)
  14. Leather Strapping (for utility belt and shoulder harness)
  15. Belt from Disgusie Deluxe First Avenger Costume (Disassembled and used pieces in both belt and harness)
  16. Blue Fabric for Over Shirt (to match flight suit as close as possible)
  17. Red Fabric (for striping down legs)
  18. Velcro, thread, X-acto, Hand Drill, etc. (Any additional items required to assemble everything)

Step 3: The Over Shirt, Graphics and Straps...

Picture of The Over Shirt, Graphics and Straps...

I sketched out my idea to help convey what I wanted to a seamstress friend that was helping me (MANY THANKS!!!) She created the over shirt based off of a t-shirt I gave her as a template (I sketched in short sleeves, but these were eliminated from the over shirt). Once ready, we fitted it over the flight suit, and tacked on the straps across the stomach of the suit. AGAIN, THIS NOT MOVIE ACCURATE. The thought is that he straps, clips, carabiners, and over shirt would help to DISGUISE the zipper of the flight suit and make it appear more as a tactical suit. If you use this strapping, be sure to FLAME the ends and edges or it'll continually fray. The vertical straps were cut and stitched from the same blue fabric as the over shirt. I added the overall clips and the strap sliders to be able to connect the shirt to the utility belt, and adjust slack as needed. The vertical straps add some vertical lines to the suit as well.

Meanwhile, I produced the chest graphics in a computer design program, and printed out the paper templates. I spray mounted the templates to the craft foam sheets. Using a straight edge and x-acto knife, I carefully cut them all out. You'll notice that the two chest graphics drawings are slightly different from each other, these separate layers are meant to give the graphics some dimension when glued together.

I then used Fabric-Tac and Loctite for Vinyl to adhere them to the shirt so that no stitching would be required or show (this is still an issue and stitching MAY be required to attach them).

I also used the Fabric-Tac (and some Loctite) to glue the red striping from the waist, down the legs, to just above the knees. This can be sewn on IF you have THAT skill.

Step 4: Utility Belt and Shoulder Harness...

Picture of Utility Belt and Shoulder Harness...

CAREFULLY disassembling the utility belt from the Deluxe Disguse First Avenger costume (pictured above), the leather belt strapping (measured to size), three sets of buckles, quick links, flat head screws and nuts (as I wanted my belt and harness hardware to show), I assembled BOTH the utility belt (including the salvaged pouches) and the shoulder harness. AGAIN, NOT AUTHENTIC. I pre-drilled the holes with a hand drill, inserted the screws and finished with nuts, and used the Loctite to glue where needed.

FYI, The photo of the belt is PRIOR to installing the anchor buttons for the overall strap clips. You can see them in some of the final images later in this Instructable.

Step 5: Painting Pads of ALL Kinds...

Picture of Painting Pads of ALL Kinds...

I painted all of the pads and guards with the automotive blue. Being sure to lightly sand and clean first, and to take my time when applying thin/even coats. Also, the rubberized logo on the knee pads wouldn't hold paint (and were near impossible to remove). So, I glued them with Loctite, overlayed a pieces of aluminum foil, and THEN painted them. Made the difference.

Step 6: Test Fit...

Picture of Test Fit...

I test fitted the suit with the half shirt and graphics. I then added the gloves and the boots. Satisfied with the results, I added the forearm guards, knee and elbow pads, utility belt, shoulder harness, and even the helmet. NOTE: The shoulder graphics were NOT installed in these pictures. These were pre-glued, and attached to the flight suit shoulders while I was wearing the half shirt, so that they could be aligned with the chest graphics. At this point, I decided to eliminate some of the smaller "fiddly" shoulder pieces. FYI, both the flag and SHIELD logo/icon are attached with the Velcro that they were supplied with.

Step 7: Test Drive...

Picture of Test Drive...

Happy with the results, I took the suit for a test drive at a comic con (pictured above). Though I only wore it for a couple of hours, I received LOTS of positive comments, and it was VERY comfortable to wear.

NOTE: There continues to be some MINOR issues with separation of the chest and shoulder graphics from the suit, but it's nothing that touch up with the glue can't solve. Again, I have considered stitching them in all of the corners to prevent this further...

If you need ANY additional information, or details, or pictures, then let me know. I'll do my best to help out!

Also, due to how dark the fabric is, I'd HIGHLY suggest taking a lint brush/roller with you any time you plan to wear the suit. as the suit picks up EVERY bit of lint and dust around!


IAmBuckeyB made it! (author)2015-09-01

I dod minw a bit differenr, but i used the same idea you did. I used a thermal shirt and an old t-shirt. I cut up a pair of cheap suspenders to make thw red parts, and an ild bwlt for the buckles and the grey part. My friend is making modifications to the straps on thw back, so that way i can hold the sheild while i walk around. F.Y.I we are going to see the Civil War movie in may, and aslo visit a Childrens Hospital in between our days. Thabks forbthe inspiration on the costume!!!!

RuckaFett (author)IAmBuckeyB2015-09-01

Sounds GREAT and looking GREAT too! Please be sure to let me know how it turns out. I'm working on a magnetic attachment method from my shield. So it'll just click in place and be easily removed.

RuckaFett made it! (author)2014-10-13

More Stealth Suit images from Nashville's Wizard World 2014

fordchick (author)2014-08-26

awesome was it simple

fordchick (author)fordchick2014-09-08

could you tell me what the shield is made out of and some instructions and where you got the supplys

RuckaFett (author)fordchick2014-09-09

fordchick, I did an Instructable on the shield. It can be found here...

or you can view it through my profile. FYI, I also did an Instructable on the helmet.

Hope that helps

fordchick (author)RuckaFett2014-10-02


RuckaFett (author)fordchick2014-08-26

Not too difficult, eh? ;-)

fordchick (author)2014-08-26

awesome was it alot of money or was it cheap

fordchick (author)fordchick2014-09-08

awesome thanks but what was the foam for

RuckaFett (author)fordchick2014-09-09

fordchick, read through to the following...

"Step 3: The Over Shirt, Graphics and Straps..."

Further down it explains,

"Meanwhile, I produced the chest graphics in a computer design program, and printed out the paper templates. I spray mounted the templates to the craft foam sheets. Using a straight edge and x-acto knife, I carefully cut them all out. You'll notice that the two chest graphics drawings are slightly different from each other, these separate layers are meant to give the graphics some dimension when glued together."

Hope that helps.

RuckaFett (author)fordchick2014-08-26

It wasn't super expensive, but I could give you a rough estimate of all the materials I used.

fordchick (author)RuckaFett2014-08-29

thanks if you would please tell me a price idea estimate and where you got all the stuff thanks

fordchick (author)2014-08-29

thank's pleas if you would you give a price idea what supplies and where you bought it

RuckaFett (author)fordchick2014-09-03

This is an APPROXIMATE price list. I always try to use things I have available. So, be sure to substitute where you want to or see fit to...

1. Navy Blue Flight Suit ($39-$45 on

2. Under Armor Brown Leather Gloves ($30-$35 from Bass Pro)

3. Palladium Brown Leather High Top Boots (Already owned but $75-$125 from

4. Skateboard Pad Set ($10-$15 from Kmart)

5. Knee Pads ($4-$5 from Lowes/Home Depot)

6. Soccer Shin Guards ($4-$8 from Academy Sports)

7. Various Buckles & Clips (JoAnn's is JUST a fabric store):

a. Fashion Belt Buckles ($5-$8 each from JoAnn's)

b. Plastic Clips ($4-$5 from JoAnn's)

c. Black Carabiners ($1-$2 each from Lowes/Home Depot)

d. Quick-Links ($1-$2 each from Lowes/Home Depot)

e. Overall Buckles ($4-$5 each from JoAnn's)

8. Black Nylon Belting/Webbing (Bought for a PER YARD price at JoAnn's)

9. White Craft Foam Sheets ($2-$3 each from JoAnn's)

APPROX. TOTAL $226-$316 +/- for listed supplies

10. American Flag and SHIELD Logo Morale Patches ($3-$4 each on

11. Blue Automotive Spray Paint ($7-$8 from AutoZone)

12. Loctite for Vinyl ($6-$7 from Lowes/Home Depot)

13. Fabri-Tac Glue ($13-$15 from JoAnn's)

14. Leather Strap ($15-$20 from JoAnn's)

15. Utility Belt from Disguise Deluxe First Avenger Costume (ONLY used belt, but ordered entire costume online)

16. Blue Fabric for Over Shirt (Bought for a PER YARD price from JoAnn's)

17. Red Fabric for Leg Stripes (Bought for a PER YARD price from JoAnn's)

18. Velcro ($3-$4 from JoAnn's)

19. Thread (Already Owned)

20. X-Acto (Already Owned)

21. Hand Drill (Already Owned)

Cool! I like that you were able to use things that were easy to find too!

I always try to do that, in case I need to do a repair or make a replacement. Besides, my fabrication skill set is kinda limited...

JuliaW59 made it! (author)2017-08-10

When I made this, I used dark blue coveralls from Amazon, and just sewed the pockets shut. For the craft foam, I highly recommend using PlastiDip (either the clear or white kind) to cover the star detailing, after you cut it out and glue them together, but before you attach it to the actual suit. It'll help the foam look cleaner and last longer, and it's like $6 a can from Wal-Mart. here was a zipper down the front of the coveralls, though, which I just worked around by only gluing the star to one side of the chest, then fixing it down with velcro on the other side of the zipper. I added a foam muscle suit underneath ( to look a little closer to the Cap we know and love. This tutorial pointed me in the right direction when I had no clue where to start, and it was pretty easy and affordable!

RuckaFett (author)JuliaW592017-08-10

That's great! Even more so since you added your own variations to the design. You should consider investigating both my personal Captain America Nashville Facebook page, where you can see all of my other suits, and the Build A Better Captain America Facebook page. I'm an administrator on there, and it has lots of useful information on build materials and products. All the best, and rock on in you Cap suit!

RuckaFett (author)2017-06-06

ROCK ON Courtney!

courtney_vh made it! (author)2017-06-04

I used your templates and instructions for making the stars & stripes for the chest! I would have done the shoulders too, but I ran out of time. Thanks for sharing such a detailed plan!

RuckaFett (author)courtney_vh2017-06-05

That looks GREAT! What are you putting the suit together for, an event or just for fun?

All the best!
Tim Rucker

courtney_vh (author)RuckaFett2017-06-05

I put it together for my first comic con. Overall a great success!

Thanks again for sharing!

courtney_vh made it! (author)2017-06-05

I used your templates and instructions for the star & stripes on the front/chest piece. Ran out of time to do the shoulders. It came out perfect! Looked great, got lots of compliments. Thanks for sharing!

RuckaFett (author)2017-04-14

Hey, and thanks for reaching out! I actually have MANY suit upgrades that I haven't documented here on Instructables, but are on my facebook page,

Remy1089 (author)2016-10-25

Are you renting the outfit for a fee at all?

ryanman1717 (author)2016-09-19

What's the total cost on this?

JediMasterG (author)2016-06-16

Exellent job man

Keep up the good work!

RuckaFett (author)JediMasterG2016-06-17

Much appreciated

MikeA11 (author)2015-04-15

Do you have the files for the Chest Graphics? Or if you are un-willing to part with them, can you tell me what program you used to make them?


RuckaFett (author)MikeA112015-04-15

Sure! I have them and I'll be happy to send them to you. I've included both .jpg and .pdf formats. I'll also let you know that I generated them in Adobe Illustrator. If that helps at all. Let me know if you have any other questions.

messijr (author)RuckaFett2015-10-07

thank you, you are really helpful! I am just wondering what is the difference of chest and chest 2? and are they up to scale? can I just print them out and trace them to some foam board?

RuckaFett (author)messijr2015-10-12

"Chest 1" is the bottom layer of the star and stripes. "Chest 2" is the top layer. I did two layers to add some thickness and depth

MikeA11 (author)RuckaFett2015-04-15

Thank you so much! You're the best.

messijr (author)2015-10-06

thanks man you are amazing! I have made my own captain America helmet and shield. so I am going to be captain America in this Halloween! I will follow your great tutorial. thank you very much!

jeditanker72 (author)2015-09-28

Awesome job! I decided to be Cap for Halloween, and I purchased a few things to throw something together, but after looking at your and others instructibles I may start over.

RuckaFett (author)jeditanker722015-09-29

Thanks! Cap is a GREAT character to suit up as. Best of luck with whatever you decide to do. Also if you need any additional reference, I have a facebook page called "Captain America Nashville". There's lots of photos of my various Captain suits, along with others.

timmyisebola (author)2015-06-15

could u please tell me how you made the super soldier costume and what would i need

RuckaFett (author)timmyisebola2015-06-15

I can tell you that my version of the "First Avenger suit", which I call the "Super Soldier suit", has been an evolution. It's my own take on the "First Avenger suit", and a more modern look than the movie. It's been my favorite of my Cap'n suits, so I've been hesitant of doing an Instructable on it.

It started off as an off the shelf suit, "Disguise's Deluxe First Avenger" suit. Honestly, it was a piece of crap! Basically a jumpsuit that zipped up the back. So, I cut off everything from below the chest (blue to white transition). I even took the zipper out of the back and the original strapping off of the front of the shirt. I bought my own pants (originally blue track style pants without any markings or logos). I've since upgraded to a pair of snowboard/rain gear pants. The pair I found is a dead on match in color for the blue upper shirt. There was however, a HUGE logo on the leg! So, I covered it with a Cap'n shield patch. You can really use whatever you like the best.

I made my own utility belt/holster and shoulder harness. The shoulder harness is a lifting harness that I found at Lowes/Home Depot. I connected the red straps, which are just suspenders cut to the appropriate length, with quick links. You can find those at Lowes/Home Depot as well. I use the clips from the suspenders to attach the harness to my utility belt/waistband. The utility belt is black webbing and inexpensive cell phone/camera pouches. The holster was on clearance at Wal-Mart.

The plastic elbow pads and knee pads are exactly that. I looked for blue ones, but that can be difficult. So, I painted them to match my helmet color. The plastic forearm guards are soccer shin guards that I painted the same red as my shield. I looked for the plainest ones that I could find. That way, there wouldn't be any names or logos that I'd need to conceal.

As far as boots go, maybe consider Palladium high top boots with a leather cuff topper. They are really comfortable! I used to wear them with this suit (I'm wearing them with the Stealth suit and my new Age of Ultron suit), but I changed to the custom red boots that I made for my Avengers suit. They were originally very sloppy! So, I bonded the boot covers to a pair of black rubber rain boots using Loctite for vinyl. I painted the fabric on the back half of the boot covers with red and maroon acrylic to match the latex front half.

For gloves, I bought football receive gloves. Under armor makes some great ones. I bought a pair of brown Under Armor gloves for the retro look, but I've switched to the Under Armor Cap'n themed gloves that I'm currently using. These were kind of expensive, but they've held up well.

Once you've read through all of this, let me now if you have any questions. also, you can follow me on my "Captain America Nashville" Facebook page. I've got TONS of photos of all of my suits on there. All the best!

timmyisebola (author)2015-06-15

Hello i was wondering if you made captain americas suit from avengers

RuckaFett (author)timmyisebola2015-06-15

The Captain America suit from the first Avengers movie was a purchase. It was Disguise's Theatrical Edition Captain America Costume...
I upgraded it with a better latex helmet...
I bought better gloves...
I did make my own utility belt and made boots out of the red latex boot covers that came with the Disguise costume. Hope all of that helps, but let me know if you have any questions.

lynx2676 (author)2015-05-03

you are missing one of capt's key items in your costume..... a gun (fake of course)

RuckaFett (author)lynx26762015-05-04

Thanks for your comment. I don't carry a sidearm with the stealth suit, as it was loosely based on the movie version from Winter Soldier. Cap wasn't carrying any weaponry, but his shield in that movie. If you look at the photos of my other suit, which I call Super Soldier, you can see that I do carry a side arm with that one.

RuckaFett (author)2014-11-04

More Stealth Suit images from Nashville's GMX vol 6 2014

About This Instructable



Bio: Hey! I'm FINALLY signing up for an Instructables account, even though I've reviewed items on this site for a while. I've made ... More »
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