Last Christmas I promised a couple of my friends I would make them Dark Knight costumes for Halloween. It seemed like a long time away but I ended up needing every minute of it.
This is my first time ever sculpting and making molds. I hope I can offer some insight on the process. First tip : It is going to take you WAY longer that you think.
This could litterally have hundreds of steps so I am going to show you the things that have to be made. Each piece could be a separate intructable. If you have any questions on any one step just ask.
I am going to organize the steps in order for them to make sense but I was sort of making all these things at the same time.
What you need:
Lots of space
Oil based clay (I used about ten pounds of Monster makers clay and 10 pounds Chevont clay plastiline)
150lbs Ultra cal
5 gallons Black liquid latex (about 2.5 Gallons per suit)
Loctite Professional Super glue (dont even try with any other super glue)
5 yards Black Mesh (for the mesh undersuit)
5 yards black Velvet (Jo-anns)
longs sleeve black compression shirt and pants (for the screen printed undersuit)
Screen Printing tools (optional)
Duct tape Maniquin
Three Rubies adult Dark knight belts
Gotham 100 boots
Purchased screen accurate Cowl
a very supportive and patient wife.
Step 1: Under Suit
I made two different undesuits. One is mesh and is more screen accurate. The other is screen printed compression gear and is more comfortable.
I had no experience in sewing so I looked to a family friend to help. Basically a full body mesh undersuit has to be made and all the armor is going to be glued to it. We used a pattern from a womens jumpsuit.
The under suit has to be skin tight. Since the material has give but no stretch it basically had to be sewn on him. This is the way to go if you have the skills to do so. We added spandex in the crotch and waistline in order to give it stretch where it needed to be.
The other option is to just use compression shirt and pants as the undersuit. Luckily for me I own a screen printing press so I was able to add the pattern to the shirt and pants.