Instructables
Picture of Sam Flynn Suit from TRON Legacy

Okay all... so more than a few people have asked for this Instructable.  I hope I am able to explain enough.  Sadly I didn't completely document the whole process, but here it goes!
 
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Step 1: Electroluminecent Tech

Picture of Electroluminecent Tech
EL_sheet 002.jpg
EL_sheet 001.jpg
EL for short, comes in many different forms.  Sheets, strips, tape, ribbon, even flexible fabric (although I didn't discover this version until after my suit was made.)  The version I used was a cuttable form I first saw on a webseries on Revision3 internet TV.  I found it on the site: http://electroluminescence-inc.com/

Attached are some photos.  The checked pattern around the perimeter alternates the connection points (anode + / cathode -) which allows the sheet to be cut so long as two opposite contacts are connected to the sheet.

Step 2: Shapes and things

Picture of Shapes and things
Tron_layout1 003.jpg
Tron_layout1 002.jpg
Tron_layout1 001.jpg
I designed the pattern on a computer after many measurements.  I cut them out on paper and layed them on the suit to ensure everything fit right.  It probably took 5 tries to get the shapes just right.  I was also trying to use as little of the EL material as possible as the sheets are almost $50 for an 8.5" by 11" sheet.

Once I was confident that:
1.  the shapes were just right.
2.  I had two contacts (+/-) connecting to each shape.
3.  I could wire them all together easily in the suit based on the current configuration.

I had my girlfriend cut them out! haha.  Seriously, she's good with a blade.
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Doctor089 months ago
What kind of jumpsuit did you use and the name of it
is there a download for the light patterns?
boltoms2 years ago
amazing suit! if you want yours to be just like the movie try using a hexagonal stitch spandex jumpsuit with a heavy industrial gloss. you can use a p33 9v battery to power the whole suit. that was held by a mount in the back (which also housed the identity disc; held on to the mount by using magnets)
Jsquared243 years ago
Best.Tron.Outfit.Ever.
needs to be skin tight, other wise cool costume
I agree!
Maybe using a diving/jump suit or thermal cloths would be a great idea instead of a leather jacket
SPANDEX! lol
taz13283 years ago
Hey. Nice job on your costume! Quick question...how many sheets of EL paper did you need for it? Just trying to get a rough estimate on the damage to the wallet. Haha.
Tifetup (author)  taz13283 years ago
I used about 5 of the largest cut and shape sheets at $50 a piece. I would wait a bit though. That same company is coming out with a pre made Sam Flynn pattern that will make the suit a lot easier.
yeah for about 530 bucks... im working on making a quorra costume. ive never worked with this stuff before. she has less illumination on her suit so how many sheets would you suggest?
tebright13 years ago
How well did the paint work on the suit?
Tifetup (author)  tebright13 years ago
Any paint peels off leather after much bending. The "Plastic Dip" paint was a little better. Good for one Halloween night, but not for repetitive use. It will always require touching up. It you are good at mixing paint you could try rubber cement mixed with a certain type of paint, but I'm not sure it would work any better. Leather and paint just don't mix.
actually painting leather is fairly easy. it isnt 100% fullproof to all benting but if you wipe down the leather with acetone then paint it, it will not chip nearly as easily
menahunie3 years ago
I used shoe dye instead of paint..
They come in plastic squeeze applicator bottles.
schroedc3 years ago
thank you for creating what I started to, but financially could not continue. I was even looking at the same company for the panels. I'm really glad someone completed my shared vision!

PS> I bought a black leather motorcycle suit for my base...
Was the entire costume made out of EL tape or EL panels? because I was looking into making a Quorra costume, but I'm not sure how you would bend the tape in order to create the curves and such. I really want to find a way to make the tape work if i can
Amazing Right!?
http://www.ebay.com/itm/EL-Tape-Curve-Tron-Costume-2cm-12cm-Bend-Half-Way-Halloween-/150671860380?pt=Adult_Fancy_Dress_UK&var=&hash=item68c8730831

http://www.ebay.com/itm/4-X-EL-Curve-Tape-Tron-Costume-2cm-12cm-Bend-Half-Way-Haloween-/150671916660?pt=Adult_Fancy_Dress_UK&var=&hash=item68c8733e5f


http://www.ebay.com/itm/EL-Hoop-Bright-Glowing-EL-Tape-Ring-Tron-Disc-Fancy-Dress-Costume-/150671711652?pt=Adult_Fancy_Dress_UK&var=&hash=item68c8729399
Tifetup (author)  sd2kool4u3 years ago
Yea, everyone is coming out with their own inspired stuff.

These are the people I've been working with.

http://e-luminates.com/osc3/product_info.php?cPath=39&products_id=106

The images from the website are from a first prototype. Click the link in the text to see the newest version. It is going to look awesome when done and I am trying to convince them to get the price down. It is way too much.

I'm sorry to say that they are not going to make production for Halloween this year...it is sad. Maybe they'll have something by Christmas.
Tifetup (author)  llaurencelle3 years ago
I used custom cut panels to create the complex shapes a year ago. Nowadays you might be able to buy precurved strips.
Tifetup (author)  llaurencelle3 years ago
Panel. But special ones that can be cut into almost any shape. Tape will work, but you may not be able to cut it based on the type.
Do you know what type of tape it is I'd need to be able to cut it?
Tifetup (author)  llaurencelle3 years ago
You'd have to test it by cutting a sample, ask the seller,or look at how it is wired. I'm sorry I can't help without an image of the piece. I believe the ones sold by glow hut are cuttable. There is also a girl who made a costume on Fashioningtech.com
sd2kool4u3 years ago
http://www.aradanicostumes.com/disc_mount?keyword=tron&category_id=0

this is what i use
Tifetup (author)  sd2kool4u3 years ago
This item is almost exactly the same as mine, but I did not have a hook at the top. If you use four magnets inside the disc and four matching in the holder, the hook is unnecessary. The hook also seems to depress the switch, or the button needs to be removed to use this holder. Im not sure of the intent and the website doesn't explain. Mine was custom made in CAD over a year ago.
sd2kool4u3 years ago
where did you get your suit
delgeezee3 years ago
too expensive! how many sheets did you use?
wclark53 years ago
hey Im working on one now and I found the perfect material my surfing wetsuit
Tifetup (author)  wclark53 years ago
Sorry i have not written in a long time. Ive been pretty busy. I'm not allowed to spread rumors, but I know of a company that is making full EL kits of Sam Flynns suit...stay tuned
rwerts Tifetup3 years ago
Please post more info once you get them. I'm looking into making one for halloween this year.
verry nice work
dprasetyo13 years ago
awesome costume.

can u tell me ,how to buy el wire sheet like that.

i cant find it in my country....

or maybe you want to sell that.

heeeeeey i finally found http://e-luminates.com/osc3/index.php?cPath=26&osCsid=4831656a4ff37ba1e0796e077cfc856c
how do you actually connect the wires to the el tape
urtlesquirt3 years ago
Love the movie, love the costume.

If I have the time to make it, I might be Clu for Halloween.
Maybe you could use copper tape to travel all the way down the back of each individual piece (Like the copper wire "fan" they used on the site; http://electroluminescence-inc.com/customPattern2.htm).

This way, if it was the black terminal that ripped and rendered the piece useless, the copper wire/tape would connect the pieces. Not only that, but it would also prevent excessive bending, at the sacrifice of a nominal amount of flexibility.

(That way, your 100s of $$$ spent will last longer than halloween! :D Great tutorial man, and THE BEST suit recreation I've seen. You're mighty creative)
nice suit, but the step 1Electroluminecent Tech could be more detailed ...
I am trying to plan out a Tron Legacy costume, but want to have the details in red. I had originally been planning on using the EL tape, but I'm having a tough time finding tutorials on how to create any kind of a shape other than a straight line. As far as I can find, the sheets are only available in blue and pink. Do you think a transparent adhesive vinyl could be placed over the top of the EL sheet to change the color?
Hi! I have a question on this part of the design, as it stumps me the most right now. You said that you designed the pattern on a computer. What program did you use? Also, where did you get the illustrations above that you drew the pattern on? Thank you! :)
I used the drawing part of SolidWorks. I know it is a little overkill, but it was the only drafting program I had easy access to. The illustration for the patterns was just a google search for an image of the human outline.
archangl3 years ago
You said that you can get flexible fabric EL, I've only known about the sheets and tape too, where can you get the flexible fabric?
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