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.

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.
<p>Where will I find the articulating hand from step 6?</p>
could you use standard eva foam mats or is that to small
<p>I love it. I know I'm a bit late to the party but what kind of pvc is that? Ive looked around but cant find anything about how strong it is. </p>
<p>At the first Step there is a Link for the Material</p>
<p>Thats the best Tutorial so Far, and I will use half of the Points here for my self, because I will use another Material with the Foam together, but this Tutorial will Help me a lot with my own Project, Thank you for your wonderfull and Inspiring Work.</p>
<p>Any idea on how to make the head? Preferably a terminator?</p>
<p>Hey angryrobot17, A while back I found another prop builder who did a terminator helmet. While it's not the same method he does have a link to the pepakura files. If you do some hunting you can find all of them for the whole armor suit. see this link;</p><p><a href="http://protagonist4hire.blogspot.com/2012/01/prop-building-101-part-1-building.html" rel="nofollow">http://protagonist4hire.blogspot.com/2012/01/prop-...</a> </p><p>The pepakura file link is in the first paragraph</p>
<p>i am too short, i'm like 5'6&quot;. 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.</p>
<p>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!</p>
<p>did the plasti-dip spray make the armor hard or is the armor still soft like the foam?</p>
<p>What kind of caulk did you use to fill the seams?</p>
<p>looking for the pep files....</p>
<p>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.</p><p>Cheers</p>
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!
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.<br> <br> <a href="http://www.youtube.com/user/gsterley/videos" rel="nofollow">http://www.youtube.com/user/gsterley/videos</a>
I will try and post an instrucatable on the Power fist itself soon!
<em>That's</em> the part I want to see. I will be waiting with bated breath.
<p>The power fist instructable is now up! </p>
<p>This would be of GREAT help. Thanks agian for sharing all the info you have on the Crusade Forums. Very helpful even as such!</p>
<p>can't wait for the Power Fist Instrucatable. Great job on the Space Marine.</p>
<p>do you have any video that you can add so we can see it actually moving around ?</p>
<p>There is a good deal of footage on my youtube channel with me walking around at cons. Just search for Gary Sterley on Youtube :)</p>
Also does anyone know we're I can get a spray to coat the foam so it does not obsorb paint?
<p>Plasti-Dip, just don't use the spray kind, it'll eat the foam.</p>
<p>This is true of traditional spray paint. However, the spray on plasti-dip will not melt your EVA foam. </p>
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?
<p>Hi there, Love the suit!<br>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?<br><br>Thanks for any help :)</p>
<p>I love warhammer 40k</p>
<p>me and my brotherinlaws like warhammer and wear going to do this</p>
<p>this is amazing</p>
<p>liked! also liked the comment below ;)</p>
<p>You're the artist born. I followed this over from the powerfist link just to see what you made. And it's jaw dropping. I envy your abilities. </p>
Wow... I am so amazed dat I could suck farts out of a seat cushion
<p>wow I am speechless! This is just amazing! You are so talented. My son just asked me: &quot;Please tell me you can make that for me?&quot; Lol!</p>
<p>Holy cow, that's impressive, no more heresy. </p>
<p>the heretics won't know what hit em'</p>
Congrats on your win at Miami. It was awesome seeing it on heroes of cosplay.
I was watching heroes of cosplay I saw the same exact costume on tv<br>
Wow amazing! The looks on some off the faces in the clip are just priceless!
<p>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? </p>
<p>Very NICE</p>
<p>there is no chance in hell that I could make it but that is awesome! !!</p>
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
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?
What did you end up using to cut the foam? My cuts don't seem fluid
<p>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..</p>
where did you get the PEX tubing from? what sort of thickness is best? and is it costly? (sorry for the multi question)
<p>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.</p>
like your stilts from pvc got to try it on my iron giant, was it easy to walk on?

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