Instructables

Gary Sterley's 40k Space Marine

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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). 
 
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Step 1: You are probably too short.

Picture of You are probably too short.
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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.

Step 2: Pepakura Patterns and Foam

Picture of Pepakura Patterns and Foam
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The suit is made of foam and uses pepakura patterns First you are going to need pepakura patterns. The ones I used can be found here:
http://www.therpf.com/f79/jfcustoms-foam-files-im-not-starwars-thread-please-get-me-back-home-148889/

The foam I used can be found here. You will need 6 sheets 1/2" thick foam, measuring 72"x48" each!
http://www.foambymail.com/MC2-.html

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.
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Jobar0078 months 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)  Jobar0078 months 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.

http://www.youtube.com/user/gsterley/videos
gsterley (author)  gsterley8 months ago
I will try and post an instrucatable on the Power fist itself soon!

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.

That's the part I want to see. I will be waiting with bated breath.
ncanfield1 month ago
Congrats on your win at Miami. It was awesome seeing it on heroes of cosplay.
cameron331 month ago
I was watching heroes of cosplay I saw the same exact costume on tv
amulder11 month ago
Wow amazing! The looks on some off the faces in the clip are just priceless!
syke251 month 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?

ALECIALLEY2 months ago

Very NICE

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

Dragon Bomb5 months ago
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
mlynch106 months 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?
mlynch106 months ago
What did you end up using to cut the foam? My cuts don't seem fluid
gsterley (author)  mlynch106 months 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..

bsuch7 months ago
where did you get the PEX tubing from? what sort of thickness is best? and is it costly? (sorry for the multi question)
gsterley (author)  bsuch6 months ago

The PEX tubing is available at home depot. The pipe itself is cheap, but the connectors are expensive. I 3D printed all of my own for this reason.

Luis Linares6 months ago
like your stilts from pvc got to try it on my iron giant, was it easy to walk on?
gsterley (author)  Luis Linares6 months ago

It's not hard, but it takes some getting used to to make it look natural. I get around pretty well, just don't plan on going anywhere in a hurry. Here is a video : http://youtu.be/YsRPEkVRaDY

That.is cool.
beuwolf13126 months ago
ok how much do you think it would cost to make one without 3d printing
rcookman7 months ago
Im still working some spots with heat gun. Considering using StyroSpray coating on it, they sent me a sample and it brushes on and hardens into solid plastic. It's supposedly sandable afterwards so I'm curious to see!
rcookman7 months ago
Started mine last week! This instructable has been super helpful! Stilts are built and inside, next is the waist. Any extra pointers for the torso?
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Hey, do you think you can do a instructable on the 3D printed fist?
JonathanWells8 months ago
Unbelievable work. You should do this for a living.
poofrabbit8 months ago
Congratulations on being a finalist in the Halloween costume contest! Can’t wait to see if you win good luck!
gsterley (author)  poofrabbit8 months ago
Thanks very much! Fingers crossed :)
poofrabbit8 months ago
Congratulations on being a finalist in the Halloween costume contest! Can’t wait to see if you win good luck!
soulcalm8 months ago
Firstly the amount of work that has gone into this is astounding, secondly it is pretty awesome. I saw you mention you were thinking of putting up a second just on the fist? That would be awesome, I'm considering doing a commissar and a moving power fist would be... Pretty damn cool. Again, awesome.
The Rambler8 months ago
Ha! Looking at this here makes the whole process look overly simplified and easy compared to actually having followed the build over on therpf.com. Welcome to instructables though. You've definitely got my vote.
gsterley (author)  The Rambler8 months ago
Lol, Yes, it is most certainly the abridged version.
ghaines18 months ago
Honestly, you should advertise this or do an auction or something to advertise that you will build these for money. Seriously, there are people who would pay you a few thousand plus expenses. Assuming there are no copyright issues, you should be compensated for your talent.
gsterley (author)  ghaines18 months ago
It could be lucrative, and I have been asked on a few occasions, unfortunately Games Workshop would not look kindly on me profiting from the building of such costumes. They are rather protective of their IP.
ghaines1 gsterley8 months ago
I have a friend who is a VP at a BIG game multi-national. He suggests finding a nice person at GW who would want to buy some of your suits for conventions and such. Of course, if you get a meanie, they could go weird and call legal. Either way, you did a spectacular job.
There will be copyright issues. But the best defense in copyright world is the same as on the net: obscurity. Then again, have you considered applying for a job with a studio or even better as a vendor for video game publishers?
Check out Harrison Krix over at Volpin Props. Maybe he's got a job for ya??
erikpet8 months ago
Loved this one! Great work good sir! I also like that yours is the first one I haven't seen using Fiberglass since I haven't really wanted to work with that material.
wmorey378 months ago
I went through your steps for about 10 minutes and im pretty sure that your favorites went up by a 25 count lol. You do exquisite work sir. This isnt short of perfection.
karnold708 months ago
Duuuuuudde. Completely amazing costume. PLEASE understand that I'm humbled by your skill, commitment and skill level. My ONLY very quiet suggestion is, "Lights make everything better." Some led's on your gun and suit would have been an added element (although, you did say that you got it done JUST in time for Halloween, so maybe, for next year?)
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