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How to make a Gort costume

How to make a Gort costume
Every year I celebrate Halloween, by making a new costume. This year, I chose to make Gort. If you don't know who Gort is you soon will. A remake of the 1951 classic science fiction movie "The Day the Earth Stood Still" is due out in late 2008. It stars Gort.

Since my software team named our new development branch Gort, this further strengthened the case for doing Gort. But you don't really need a reason to build a giant robot with a death ray; you just know you want to.

Here are some links for those who don't know about Gort or want some pictures to guide their own construction.

A site dedicated to Gort

A Flash site with many robots including Gort

"The Day the Earth Stood Still" clip

 
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Step 1Materials needed

Here is a list of materials you will need.

Full Face Motorcycle Helmet: The most distinctive part of Gort is the head. The closer you can come to finding a "Gort-shaped" helmet the happier you will be. A tinted face shield is another thing you want to look for. This will hide your un-Gort like face from the world. Look for a used motorcycle helmet since you are going to be making mods to the helmet which will make it unsuitable for further use on a motorcycle. I got mine on eBay. Try to get one a fair bit bigger than your hat size as this will provide room for your head and Gort's death ray gear.

Gort pants: An old pair of gray fleece sweat pants are what I used. Gray seemed a good choice because they are going to be painted silver. Other colors would be harder to cover. Avoid pants with obvious pockets, seams, etc. You are after a solid "robotic" appearance.

Gort top: A gray turtleneck is what I used. Gray for the same reason just noted. A turtleneck has no buttons detract from its "roboticness" and best of all you can unroll the turtle-neck up into the bottom of the helmet to create a solid appearance from your body into the helmet.

Gort boots: Gort wears some serious stompers. I was lucky and had an old pair of Ugg-like boots (suede exterior, fleece interior) that were not used anymore. If you lack such, you can probably find rubber gardening boots for not too much money at surplus stores.

Balsa wood: 1/4" x 4" x36" piece of balsa wood. You only need about 18" long but the craft store had it in 36" lengths. Used to make Gort's ears.

Silver spray paint: Two cans of Rustoleum(tm) or similar brand silver (shiny type not just gray) paint

Gray felt: Used to make Gort gloves and Gort waistband. Amount needed will depend on your hand size and waist size. Gray color for the usual reason. They are going to get painted. More on this in the associated steps.

Foam: Used to make Gort's belt

9 volt battery: Used to power Gort's ray of destruction. Amazing what you can do with just 9 volts.

Coat hanger: Used to mount Gort's death ray generator in helmet

9-volt battery connector and leads: What you hook the 9 volt battery to. It has two wires leading from it and you attach your wiring to them. Local electronics supply store will have them

2.5 volt Christmas tree lights: Illumination for Gort's beam. Look in your Christmas box for all the spares you probably have. You will need 4.

Glow stick tube: Used glow stick tube to hold the lights (or other similar translucent tube). Feel free to improvise on this one

Plastic-coated wire: Your basic bell wire used to build the circuit from the 9-volt battery to the switch and to the Christmas tree lights

1 Gallon empty plastic milk carton: Source of raw material for the switch to activate the death ray

Aluminum foil: Small quantities for backing the lights and for making the switch. Also used to cover the helmet face shield so you don't paint it by mistake.

Masking tape: Also used in masking off parts of the helmet you don't want to paint.

Needle, thread, scissors: Usual sewing implements. Not a lot of sewing and certainly nothing fancy required.

Solder, soldering iron: Not critical but your circuit is less likely to fall apart if soldered.

Sharp knife or single edge razor: For cuttng foam

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8 comments
Aug 22, 2009. 9:55 PMEye Poker says:
Awsome!
Dec 7, 2008. 8:14 AMcreaturerevenge says:
Wow! Major points for making anything to do with 'Day"! Nobody ever seems to do anything related to that film! It's such a classic! As soon as I have some more free time I am going to make a full size statue of him. He is a charecter I have always wanted to build! Great job!
Nov 4, 2008. 11:50 PMDIYADD says:
Gort! Klaatu Barada Nikto!
Nov 1, 2008. 4:10 PMGorillazMiko says:
Very very cool. GORT GORT GORT +5/5 stars.
Nov 1, 2008. 3:17 PMsr1sws says:
Gort RULES!
Nov 1, 2008. 2:01 PMCharlie_Szasz says:
My god. YES! It's my favorite black & white movie. :D
Nov 1, 2008. 7:40 AMxrobevansx says:
Daft Punk must like 50's sci-fi
Nov 1, 2008. 5:09 AMgmjhowe says:
haha great work! well done.

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