Picture of Voltron Force (5 Person assembling Epic Costume)
Voltron Force
(A Crazy Ray Production)
Hello everyone, I am known to all my friends as Crazy Ray. I would like to start by telling you how I was motivated to make a 5 person assembling costume named VOLTRON FORCE. I was at a Halloween party when I saw some of the most inspiring costumes. I decided to make a costume that was dear to my heart and what better costume to choose then the DEFENDERS OF THE UNIVERSE! Woop woop!!!!
Making a 5 person costumes in a matter of 2 months was definitely pushing it. Don’t get me wrong, I was doing 10 months of research and advance purchases building my game plan. I built this costume all by myself inside of a 2 car garage.
I used a wide variety of all build techniques: Foam cutting and gluing, fiberglass, sewing, liquid plastic coating, riveting, bolting and painting. My hands hurt and my body aches so I hope you enjoy my step by step tutorial.

Step 1: Step 1: Universal parts

Picture of Step 1: Universal parts
My first plan was to make all the universal parts which were the lion legs and forearms.
1. Cardboard
2. Straight edge
3. Plywood
4. band saw
5. bench sander
6. Modeling clay
I made templates out of cardboard and then copied it over to wood. I used wood to make the base of the molds. I found that the best tools for this project were a band saw and bench sander.
My next step was making the fine details with modeling clay. The Sculpy brand worked just fine. I would sculpt and heat the clay in the oven to harden it. I attached the hardened clay to the wood using a Hot Glue gun. Sorry my vacuum forming video would not upload.
snooky20051 year ago
I still have that same Voltron toy you're using as a paint reference. Thank you so much for the nostalgia feels. I love it!
xenor2 years ago
Word cannot express how epic this is. Bravo!
voltron5 (author)  xenor2 years ago
Thànk you kindly. Keep an eye out for neon light upgrades in 2014. Rock on and keep FORMING BLAZING SWORD!!!!
christzilla2 years ago
Holy crap! Are you a God of some kind?
voltron5 (author)  christzilla2 years ago
Just a proud member of the Voltron Force!!!!
solipsism2 years ago
voltron5 (author)  solipsism2 years ago
Thanks. I tried my best.
poofrabbit2 years ago
Now here is a blast from my childhood past!!! Very well done!!
voltron5 (author)  poofrabbit2 years ago
I'm blast from the past is absolutely right but this thing has live within me for the past 20 years. I had to do something with it hahaha
Excellent . .. had the same problem with video, put it up on YouTube, edit your instructable and go to the HTML mode in this step to paste in the embed code. That video would round out this instructable quite nicely. :-)
voltron5 (author)  AnubisAndIsis2 years ago
The video that I had is on file so I will have to figure out YouTube as well. I have a lot of learning to do. Thanks