Inspired by the new summer flick "G.I. Joe: The Rise of Cobra."  This instructable will show you how to create the "Duke" Armor.

So my wife and I love to go out in costume for Halloween.  I usually lean more on the side of gross and mutilated, as I have studied Special Effects and Make-up Artistry.  My wife, on the other hand will dress up as whatever, as long as it’s fun.

This year we are going to Vegas on Halloween to celebrate our 1-year wedding anniversary.  We got married there and thought it would be fun to go back.  We thought that since it would be just the two of us this time, we should dress up in a way that will compliment one another.  We thought long and hard and finally came up with G.I. Joe characters (from the movie).  If you have seen my wife, she is a dead ringer for Siena Miller’s “Baroness”.  And me?  As long as I have the suit on, I might, sort-of look like the Channing Tatum’s “Duke”.  Maybe.

Items you will need:

•Hot glue gun

•Spray glue

•1 can silver spray paint

•1 can black spray paint

•Sewing machine or a needle & thread (add about 40 more hours!)


•Blue Painter’s tape (wide)

•Self-healing mat

•4 yards black fabric

•4 yards green fabric foam

•1 roll of black craft foam

•2 sheets of thick black craft foam

•Cardboard (for patterns)


•White fabric chalk

•2 yards velcro

•4 yards black belt strap

•4 yards black elastic

•2 side release backpack buckles

Total price for materials: $87.00

Total hours worked: 30ish?

Let’s start off my examining the production shots of Duke’s armor carefully.  I tried to build it as close as I could but I had to take some liberties based on my experience at this.  But I did, however, want to make it somewhat functional.

We will be making three parts to this suit:

•Vest & Armor

•Arm Gauntlets

•Shoulder Pads

Step 1: Making the pattern.

Picture of Making the pattern.
For me, pattern making was very important.  So within Adobe Illustrator I inputted a picture of Duke and drew on top of it, coming up with this.

Orange – Top layer of thick foam

Pink – Bottom layer of thin foam

Green - Thick foam

That's so dope! Good job on the armor!
icongfx (author)  SpicyPandaCreations1 year ago
Thanks so much! It was fun making it.
CementTruck4 years ago
Hell yeah "Real Men Know How To Sew!!! A sewing machine is just another power tool.

Cool Instructable. I made my son Jango Fett armor last year using the plastic from a 5 gallon bucket. Similar idea.
tete3114 years ago
I like the 7th picture alot, it really makes the armor look its best with the lighting and the pose, Two thumbs up.
icongfx (author) 5 years ago
Hey guys.  Just wanted to let you know that I am extremelydisappointed after speaking with a few clubs in Vegas.  There is noway that I will be allowed to enter a club with my plastic guns for mycostume.  I had called the Vegas police about this and they are okwith me walking around with it as long as I am responsible enough. Is there any ideas anyone may have to replicate pistols and a assaultrifle but at the same time making it semi-obvious that it is fake?
Get a nerf gun, paint it black or what not. Be sure to put a bit of orange at the end.
rorpen5 years ago

how much for the templates?
icongfx (author)  rorpen5 years ago

$100.00 for:
•Armor front
•Armor back
•Shoulder Pads
•Tricept Pads
Kaiven5 years ago
Nice! I just realized that I don't have to put fake armor plates on an old shirt.. I can make one! :D Thanks for the i'ble! (by make one, i mean a vest/shirt)
icongfx (author)  Kaiven5 years ago
 Exactly!  I got tired of ruining my clothes.  Plus it is easy to get off and on.  If you are going to try this I have one suggestion: Make the chest armor about an inch or so smaller than I showed.  I am having a little trouble crossing my arms.  Other than that, enjoy!  And thanks for the comment.
Kaiven icongfx5 years ago
No problem, looks awesome! And I love how the foam actually looks... not porous (is there a word for that?). Did you use a vest template from a book or something and modify it, or was it all drawn yourself?
icongfx (author)  Kaiven5 years ago
 Nope.  I created all the patterns just by looking at different angles of the character and overlaying my drawings on top of the photographs for scale.  I then measured my upper body and did a few sample paper tests for the right sizing.  As far as the back goes, I was unable to find good pictures for reference so I went to the store and got an action figure for reference.  Gotta do what you gotta do!  The foam reacted very well to the silver spray paint and I think it looks cool too.  Blue painter's tape was my dearest friend!
Kaiven icongfx5 years ago
Sweet. I might eventually try this (yet another failed promise xD). It'sreally cool.
a_traceur5 years ago

8th picture is sweet! Great ible!

Papai5 years ago
excellent.....GREAT IDEA!!! thanx a lot