The Dark Knight Batsuit and Bane Mask and Costume

 by alexthemoviegeek
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With the upcoming release of The Dark Knight Rises, and the coincidental timing of my friend, Kevin, being bald from chemotherapy, we decided we should make a video. He wanted to be Bane, and I could pull off a half-decent Batman. Of course I had to make some costumes.

I started out by making the cowl. After that, I figured the suit would follow easily enough. However, the suit from The Dark Knight is quite a unique Batsuit design, and so it's difficult to make a costume of it, especially from scratch. But as always, I took on the challenge. I followed my usual goals, with a dedication to detail, a stickler for accuracy, and working quickly with a low budget.

This Instructable will show how I made the Batsuit, and also Bane's mask and costume pieces. It's more of a behind-the-scenes than a tutorial to follow step-by-step, but should provide interesting insight, and maybe help others who are looking to make a similar costume. Some of the construction processes and costume details are difficult to describe, and are more easy to understand in the pictures.

Here's a video you can follow, or watch as an introduction to the overall process. The Instructable is more detailed and has more advanced tips and recommendations.



This is the video we made with the costumes:

 
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Step 1: Materials and Cost

Material and cost breakdown for the different costume elements:

Batman
$20 Gloves
$16 Utility Belt
$12 Mesh
$10 Foamie Sheets
$8 Boots
$4 Bag
$3 Cape
$1 Egg Trays
$1 Tupperware Containers
Total: $75

Bane
$6 Shirts
$5 Lego Tubes
$4 Tubes
$4 Bag
$3 Belts
$2 Teddy Bear
$1 Foamie Sheet
$1 Metal Rings
Total: $26

Miscellaneous/Various
$7 Clear Spray
$5 Plaster
$4 Paint
$3 Glue Sticks
$2 Spray Paint
Total: $21

Total cost of materials bought for the costumes was around $122. Overall, $75 for the Batsuit seems like too much to me, but isn't bad, especially considering that about $50 of that came from pre-made gloves, belt, and mesh. I'll talk more about those pieces later, but they were definitely worth the cost.

Foamie sheets (or Fun Foam sheets) were my choice for most of the armor for the Batsuit. It provided several advantages; it's flexible, yet retains it's shape, meaning it wouldn't break or crease during movement. It would be lightweight and safe. And the pliable surface would be an advantage to adding texture or shaping armor pieces. I did have concerns about cost, as foamie sheets usually range from 50 cents to a dollar each, but I was lucky enough to discover a 5-pack of black sheets at the local dollar store. Other items were found at the usual thrift stores and craft stores.
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Carlos Marmo says: Nov 4, 2012. 6:38 AM
Wunderbar!!!
Unihorn says: Nov 1, 2012. 9:01 PM
Costumes are alright, but you should focus on the film making. That was hilarious.
smattox1 says: Oct 29, 2012. 4:45 PM
I just wanted to say thank you so so much for all the awesome work on this. Was a gigantic help for my costume. Made some slight modifications, but overall very happy with how it turned out:

https://www.dropbox.com/s/iw0lunxxq26eyyb/Photo%20Oct%2029%2C%206%2029%2035%20PM.jpg

https://www.dropbox.com/s/rlc5bevvf825nr9/Photo%20Oct%2027%2C%208%2053%2053%20PM.jpg
mbaamonde says: Oct 28, 2012. 7:13 PM
Using this guide this is what I came up with for Bane:

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/431635_10100703383081617_1765396598_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/400255_10100703709986497_1648604639_n.jpg

Extra special thanks to alexthemoviegeek for an excellent and detailed guide!

Advice to people making their masks for Halloween: I recommend lining the inside with black duck tape. If you sweat a lot it can make the paint run and can make the foamie pads wet so a line of duck tape can help with comfort.

For the tubes on the mouth I found some at a Lowes hardware store in the plumbing and electrical section, (the black wool-looking tubes) and for the others I used jumbo ribbed straws with regular straws inside them with bent metal wire inside that.

I also sewed the whole the thing together through the foam and the metal rings on top because it was very fragile and I guarantee you will be lifting it up on your head to drink and talk so it should be able to take a lot of movement.

Good luck!
mbaamonde says: Oct 28, 2012. 7:01 PM
Using this guide this is what I came up with for Bane:

https://sphotos-b.xx.fbcdn.net/hphotos-ash4/431635_10100703383081617_1765396598_n.jpg

https://sphotos-a.xx.fbcdn.net/hphotos-ash4/400255_10100703709986497_1648604639_n.jpg

Extra special thanks to alexthemoviegeek for an excellent and detailed guide!

Advice to people making their masks for Halloween: I recommend lining the inside with black duck tape. If you sweat a lot it can make the paint run and can make the foamie pads wet so a line of duck tape can help with comfort.

For the tubes on the mouth I found some at a Lowes hardware store in the plumbing and electrical section, (the black wool-looking tubes) and for the others I used jumbo ribbed straws with regular straws inside them with bent metal wire inside that.

I also sewed the whole the thing together through the foam and the metal rings on top because it was very fragile and I guarantee you will be lifting it up on your head to drink and talk so it should be able to take a lot of movement.

Good luck!
kurtnotkirk says: Oct 22, 2012. 5:04 AM
Amazing work, and the spoof trailer is excellent! Very Funny!
Add1ckted1982 says: Oct 22, 2012. 1:59 AM
hello there,

Would you be at all interested in a payment for hire of your mask for ASAP should you be situated in the UK? I need the item before Friday and I am happy to transter a substantial amount VIA PAYPAL if you wish. I will return the item after this weekend to you via registered post so I know and you know you have received the item safely. If your interested please get in touch ASAP. The mask looks incredible, well done!!!

My details are hamersleywill@hotmail.com and if you want to ring me its +447905 270009. Name is Will :)

Hope to hear from you soon .

Thanks
Christianus_Dei says: Oct 19, 2012. 6:05 PM
Another question: What are the exact measurements for the foamie and cloth at the top part of the mask? I'm guessing the tip is 1.2 in, but the rest is more troublesome.
Christianus_Dei says: Oct 11, 2012. 1:36 PM
Do you have any suggestions where I could find tubes like the LEGO peices? I have those pieces, but I'd rather not destroy somewhat hard to get LEGOs.
barista in reply to Christianus_DeiOct 19, 2012. 2:03 AM
Go here and select your local store from the link top right, if not UK and search the Pick-a-brick section for 'pipe'
123Prime1 says: Oct 3, 2012. 6:59 PM
the real bat suit has a line on the pectoral armore where the gray metal mesh pieces go how do you pu a indentation there?
Trueblueta2ood says: Aug 24, 2012. 10:11 AM
what kind of latex do you use for the mold? I've never used it before, but I'm a quick learner!
taluntain in reply to Trueblueta2oodAug 25, 2012. 6:47 PM
i think it just simple liquid latex that you can find in most costume stores :D
theEmmers in reply to taluntainSep 13, 2012. 10:19 AM
Do you remember the brand? I have never used liquid latex before and I am wary about what I buy. I don't have the funds to experiment around with the many brands I have seen out there. :\ Liquid Latex is kind of expensive.
Trueblueta2ood in reply to taluntainAug 26, 2012. 12:38 AM
Hm...somehow it looks different...I'll check around though!
starshine71 says: Sep 11, 2012. 9:47 AM
I'm not even interested in making either of these costumes, I just wanted to comment and say that you guys are awesome and I loved the trailer.
Garlikguy says: Sep 1, 2012. 10:00 AM
I followed your directions (with slight modifications) and this is what I got!
http://imgur.com/WrmeE
stidham32 says: Aug 17, 2012. 10:41 AM
Where did you get the mesh material?
stidham32 says: Aug 17, 2012. 10:34 AM
Where did you get the belt? It looks like it has actual links?
jcanning says: Aug 10, 2012. 2:24 PM
hello I was wanting to make a batman costume and I came across yours + great job on the bane mask it look very realistic any way is saw the price of the batman, I was wondering is their other way of make a batman costume for a little more cheaper the amount I was looking for is $30 or $40.

Questions:

I saw the mask build video on Youtube and how do you make the mask less glossy?

where did you got the belt from and can you send me a link to it?

how much did the making of the mask cost?

hope you can write back soon thanks.
alexthemoviegeek (author) in reply to jcanningAug 10, 2012. 9:48 PM
Most of the cost for this costume was the belt, gloves, and mesh, about $50 for those. If I used generic gloves, and didn't worry about the mesh, that would drop the budget more around $30.

I got the belt on eBay, Amazon is also a good option:
http://www.amazon.com/Batman-Dark-Knight-Adult-One-Size/dp/B001DNEE6E/ref=sr_1_1?ie=UTF8&qid=1344659969&sr=8-1&keywords=batman+belt

The mask is a little difficult to estimate cost; the main expense would be the liquid latex, which I happened to already have. But buying the latex, plaster, and clay to start mask making can put you back around $60, most of that cost being the latex. Mask-making latex is best to buy by the gallon, for about $50. A gallon of latex is enough to make several masks with, and is a good investment. Just making one latex mask and only one, though, would be at least $30.

As for the gloss, something that happened after I painted the mask, and I imagine that some sort of Mod Podge or other clear, matte coat material could reduce the gloss.
jcanning in reply to alexthemoviegeekAug 16, 2012. 7:19 PM
yup thanks for the reply. I'm confident this will help me for my batman costume

this is just a suggestion. Could make a tutorial on the 1989 batman grapple gun?

that is all thanks
solidfunk says: Aug 11, 2012. 4:42 PM
No Comment's!!! Great job looks really good!
lplace says: Aug 4, 2012. 12:34 PM
Hey, is it possible you could go into more detail on how you made the latex section of the bane mask? Thanks!
alexthemoviegeek (author) in reply to lplaceAug 4, 2012. 6:02 PM
I made it the same way I made the Batman mask. Check out the other Instructable to see that process.

http://www.instructables.com/id/Latex-Mask-Part-2-Molding-the-Sculpt-and-Casting-/
lplace in reply to alexthemoviegeekAug 4, 2012. 10:42 PM
That video answered almost all of my questions, Thanks! When you made bane's mask, did you make the clay model from the Styrofoam head or did you make another copy of your head?
tech dawg in reply to lplaceAug 10, 2012. 7:41 AM
styrofoam head is what he used for banes mask
the_real_mccoy_ says: Aug 8, 2012. 5:03 PM
You do some great stuff! if i posted half the stuff i did i would have to make a new account (sigh) back to posting
rohitk says: Jul 16, 2012. 10:27 PM
Half way through the Bane mask now, thanks so much for this instructable Alex. Incredibly helpful.

Heres a few changes i have employed, lets see how they turn out but so far been very helpful and easy especially for the novice (me):
- Skipped the latex mask because of my lack of experience with the process and lack of time (started this on the sunday before the premier of the movie). Instead used a Paint respirator found here: http://www.homedepot.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10051&langId=-1&catalogId=10053&productId=100537039&R=100537039
- Instead of lego pieces for the ribbed tubes (which were expenses because of the full lego sets) I used cheap accordion straws usually found on kid's water bottles
- Added the velcro to the back. The two ear flaps attach first then the head flap goes over it

Going to paint the mask tomorrow, give the flaps foamie detail, and add the leather straps and gromits to the top.

Thanks again, and all hail Hot Glue, saves me from breaking my back too hard ;P
lplace in reply to rohitkAug 6, 2012. 8:40 AM
Hey, the mask looks great! What materials did you use to add more detail to the respirator?
Garlikguy in reply to rohitkAug 5, 2012. 9:19 AM
Great idea on the respirator, saved me about 2 days work. Something that I found to be helpful and time saving was to, instead of drilling the Tupperware for the mouth holes, use a hole punch. Comes out cleaner, and saves a good hour in drilling and sanding.
tiltmfc in reply to rohitkAug 4, 2012. 5:43 PM
Do you have pictures of your mask?
rohitk in reply to tiltmfcSep 20, 2012. 5:21 PM
Finally added pictures of the mask i made, Thanks so much Alex for the help!

http://www.instructables.com/id/Bane-Mask-The-Dark-Knight-Rises/
rohitk in reply to tiltmfcAug 5, 2012. 10:11 AM
Here is an a fun pic of me in the office wearing the bane mask over an iron man mask.

Thanks to the big velcro flaps that hold it together in the back its adjustable to most heads.

http://i.imgur.com/UK8Q3.jpg

I will be posting a mini instructable on the mask soon
Grandwizardman says: Jul 28, 2012. 5:17 PM
Would you by chance be able to make a bane mask for sales?
I'm planning on making the vest and all, but that mask is just so complicated.
Haven't been able to find any reasonably priced masks online.
Thanks for the awesome guide by the way.
MrBrownPants says: Jul 27, 2012. 1:26 PM
Great suit!! You did an excellet job and great use of foam!! I've made my own suit but I have no costume making experience at all. Tell me what you think once I upload it!
nissan0712 says: Jul 26, 2012. 5:24 AM
would you be selling any of these masks? looks great. and how big of a head is it built for?
lcampbell8 says: Jul 26, 2012. 4:55 AM
how do you get the chest piece to give the puffed up look
aleji77a says: Jul 16, 2012. 10:23 AM
dude.... this is amazing!!! I think I love you!
you ARE my hero, lol ok.... first Batman, then you :P
ladyaeryn says: Jul 13, 2012. 11:35 PM
How did you size your gaunlets? How is your hand able to fit through after they are finished?
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