I have a full build thread located on the RPF forum here: http://www.therpf.com/f24/sylgians-4...ne-wip-179602/
an another on Obscurus Crusade here: http://obscuruscrusade.com/forum/index.php?topic=1625.0
And you can find it on facebook here: https://www.facebook.com/garysterleystudios
This was my first time working in foam and also my first time working on something so large. The costume stands roughly 7ft tall and requires that I walk on stilts. The hardest part of the whole process was probably the Power Fist (the giant left hand). I designed it in google sketch-up and 3D printed all of the digits myself. It is fully articulated and I am extremely proud of it. Designing everything in 3D was a huge hurdle. I am not a 3D modeler. I have been trying to teach myself the software though, and this is the largest and most complicated thing I have ever designed.
Total cost was roughly $1300 and it took up about 450 hours of fun (aka labor).
Step 1: You Are Probably Too Short.
Step 2: Pepakura Patterns and Foam
The foam I used can be found here. You will need 6 sheets 1/2" thick foam, measuring 72"x48" each!
Print out the templates, transfer them to the foam and get cutting! Use a SHARP knife. Replace the blade often or sharpen it as you go. Work clean though. A little care now saves you clean up later.
Step 3: Assemble Your Foam!
Use a hot glue gun to join the edges.This is going to take some time. I used over 100 sticks of hot glue once it was all said and done.... the big ones too. Refer back to the Pepakura files if you get confused during assembly.
This is a major step and is going to take a looong time. Dont rush it, work as cleanly as you can. The glue can ooze out a lot if you use too much and will have to be removed later. It takes some time to get the hang of it, but you will get a feel of how much is enough as you go.
Step 4: Reinforce the Armor.
Step 5: Embellish Like Crazy!
This is also a good time to distress the armor. I added many scratches, gouges and craters. I wanted my armor to look well used! I cut V shaped scratches with a hobby knife and even added some slagg burns with a soldering iron. Have fun with it!
Step 6: Arm Yourself.
Space Marines are going to need some weapons. Apparently, in the grim dark future.... there is only war. I 3D printed myself an animatronic Powerfist (that's a whole tutorial unto itself), and made a bolt pistol out of the same foam as the suit. There are many weapons available though and pepakura templates are widely available for them all. Have fun choosing!
Step 7: PAINT!
After the plasti-dip is dry, rattle cans are used to apply the desired colors. I used two shades of blue to add depth. A dark base coat and I highlighted the edges with the lighter shade. I then airbrushed all the recesses, seams and scratches with black and drybrushed silver where the armor was scratched or worn (mostly along the edges).
Step 8: Go Out and Enjoy Your Amazing Space Marine Costume
Recent Video: http://youtu.be/YsRPEkVRaDY
For FULL build details of my costume please follow this link!
the RPF http://www.therpf.com/f24/sylgians-40k-space-marine-wip-179602/
or the Obscurus Crusade http://obscuruscrusade.com/forum/index.php?topic=1625.0
You can also find loads more pics on my Facebook at: http://www.Facebook.com/garysterleystudios
Stop by and give me a Like :)