Picture of Gary Sterley's 40k Space Marine
This is my Warhammer 40k Space Marine Costume. It is a Crimson Fist and was completed just in time for Halloween this year. This is my second ever costume build and I have been working on it since March of 2013.

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: http://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.

Picture of You are probably too short.
Odds are you're not 7ft tall. The completed costume, built to the scale I used, is 7ft tall. You are going to need stilts. I made mine out of PVC, wood and some old shoes.
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Any idea on how to make the head? Preferably a terminator?

Dustpelt18 days ago

i am too short, i'm like 5'6". but that is so cool!! how long did it take??? i do know that that is not any space marine armor; that is the imperium space armor from the titan comics.

SeanA42 months ago

I know this is a bit of an older posting, but really want to say thanks for all the tips and step by steps. Started to work on my own, doing Space Wolves, using very similar methods to yours. Had a few suggestions from friends, such as using fiberglass cloth and drywall stilts (they have articulated bottoms). In any case, thanks for all this, and hope mine can be even half as good as yours!

lukeb103 months ago

did the plasti-dip spray make the armor hard or is the armor still soft like the foam?

Lwils5 months ago

What kind of caulk did you use to fill the seams?

looking for the pep files....

lj.schulz6 months ago

G'Day.....quick question, do have or know where i can find Gears of War pdo's, Ive tried RFP and both 405 and 501.


Jobar0071 year ago
Your powerfist is exactly what I was thinking should be done for one. I'm glad to see that someone made it a reality. I, for one, would like to see an Instructable on that if you documented it!
gsterley (author)  Jobar0071 year ago
For now you can follow the link to my build thread on the RPF.com. I have detailed progress pictures there as well as video updates on my youtube channel.

gsterley (author)  gsterley1 year ago
I will try and post an instrucatable on the Power fist itself soon!
That's the part I want to see. I will be waiting with bated breath.
gsterley (author)  bookmunkie6 months ago

The power fist instructable is now up!

This would be of GREAT help. Thanks agian for sharing all the info you have on the Crusade Forums. Very helpful even as such!

can't wait for the Power Fist Instrucatable. Great job on the Space Marine.

buffy.irwin.79 months ago

do you have any video that you can add so we can see it actually moving around ?

gsterley (author)  buffy.irwin.76 months ago

There is a good deal of footage on my youtube channel with me walking around at cons. Just search for Gary Sterley on Youtube :)

GarrettM37 months ago
Also does anyone know we're I can get a spray to coat the foam so it does not obsorb paint?

Plasti-Dip, just don't use the spray kind, it'll eat the foam.

gsterley (author)  SammyManny56 months ago

This is true of traditional spray paint. However, the spray on plasti-dip will not melt your EVA foam.

GarrettM37 months ago
I am 14 and I wish to follow these steps to make black Templar armor. Do you know how much this would cost for all of the materials?

Hi there, Love the suit!
I'm making a suit myself using this method and I'm following you on the rpf. I was you changed your design for the stills and I was just wondering what foam you used for the front section?

Thanks for any help :)

jackmaster9 months ago

I love warhammer 40k

ninjanathan9 months ago

me and my brotherinlaws like warhammer and wear going to do this

GrimButler10 months ago

this is amazing

tysonvw10 months ago

liked! also liked the comment below ;)

Bvbbuh10 months ago
Wow... I am so amazed dat I could suck farts out of a seat cushion
kcortesi10 months ago

wow I am speechless! This is just amazing! You are so talented. My son just asked me: "Please tell me you can make that for me?" Lol!

Victor8o511 months ago

Holy cow, that's impressive, no more heresy.

deus ex1 year ago

the heretics won't know what hit em'

ncanfield1 year ago
Congrats on your win at Miami. It was awesome seeing it on heroes of cosplay.
cameron331 year ago
I was watching heroes of cosplay I saw the same exact costume on tv
amulder11 year ago
Wow amazing! The looks on some off the faces in the clip are just priceless!
syke251 year ago

Do you still have the files for this. I checked the rpf and I'm having a lot of trouble getting the files to work. Any suggestions?

ALECIALLEY1 year ago


there is no chance in hell that I could make it but that is awesome! !!

Just a suggestion. Could you give a little more detail on how you made the parts and the frame work on the inside ?? Also how did you do the helmet. Your friend from the Emperor Ethan
mlynch101 year ago
Perfect. One more question. I downloaded the same file you recommended I am ha being a little trouble piecing it together. Partially because my printer does not print the cross hairs in the corners. How do you know if it is correct sizing or if I lost a small portion?
mlynch101 year ago
What did you end up using to cut the foam? My cuts don't seem fluid
gsterley (author)  mlynch101 year ago

A razor of some kind. I used an xacto, a box cutter and some of those clicky disposable razors as well. However they must be SHARP. The sharper the better. I highly recommend a fine sharpening stone. You can greatly improve the lifespan of a blade with a few swipes on the stone once in a while..

bsuch1 year ago
where did you get the PEX tubing from? what sort of thickness is best? and is it costly? (sorry for the multi question)
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