WIP Hospitaller (image heavy)

[Aurelius]

Cosplay planned for Sydney Supanova 2016
Based on the GW miniature model



Started with a felt hat base from my local art store, made a paper mock up and tested the shapes.


Did a very loose mock up with spare material in an effort to get the material to sit right.
Managed to get something resembling a pattern then transferred it to proper material, to be honest I was making this up as I went along.



It seemed to have worked, the pleating was ironed in before the full assemble and then hand stitched to make sure they stayed put and the material formed around the base.




Roughly made up a fleur de lys to go on the front, I want it to be more 3d so will probably change it up later.

[Aurelius]

Skirts and belt + crotch and hip plates.

Skirts were patterned out at a smaller scale with paper and then blown up to full size.
Back skirt is a large U shape then pleated down from 154cm wide to 60cm wide.
Front skirt is a giant triangle, that started at 110cm wide and pleated down to 32cm.
All pleating was hand stitched together than ironed down.
Fabrics used, White homespun and red Bemsilk? lining fabric.
Skirts are connected to the belt with press studs, 4 for the front skirt and 6 for the back skirt.





Belt and plating.
Patterned by wrapping mannequin in cling wrap and masking tape, while the mannequin had the corset on. Bottom of the belt lines up with the bottom of the corset.
Patterned transferred to EVA foam.
Closed at the back with velcro.
Hip plates patterned onto card, one half drawn then folded and cut so all pieces are symmetrical. Both heated slightly to give them a curve rather than staying flat.
Attachments are press studs and nylon strapping.

[CLOTHAR]

You are going to have your own army soon with all your gear sets!  I like the look of this so far.

[Aurelius]

Shin and boot covers.
Shins took a couple attempts to get right, made up of 2 parts for the main form, ankle and calf, with 3 pieces for the knee.
Zipper was installed in the back so it would be taken on and off but had to be reinforced with velcro tabs as the foam kept separating from the zipper due to how form fitting it was.



Boot covers are 4 pieces connected with elastic from the heel segment to the top plate. each section is held together with 2 Chicago screws which allow for minimal flexibility. But due to the shoes my feet don't really move anyway.



Hat update, made the fleur de lys icon and used press studs for the detailing. Hadn't been glued on yet because it still had to be primed and painted.

[Lamia]

You're the first person I know who has used the zipper on foam. What adhesive did you use? How sturdy is it?

Very exciting!

[doomfist]

Seriously, how did oyu do that?  Contact cement? 

[Abaddon Ah Cimith]

Looks like some kind of hot glue... due color, normally working with foam and some elements using temperature allows to do amazing things lol

[Aurelius]

Seriously, how did oyu do that?  Contact cement?

Yeah contact cement, though I've found because the armour is a little bit TOO snug it's tearing the zipper from the foam.

[Aurelius]

Gloves

Went through several different methods of making these before I found a method that worked.
Settled on a free pattern from this site -> http://www.armourarchive.org/patterns/












Materials used: Worbla, pair of leather gloves from Target with the lining removed, single capped rivets.

[Aurelius]

Chestplate.
Originally patterned via cling wrap and masking tape. Traced onto foam and cut out.
Used the worbla sandwich method and assembled the front and back halves with velcro straps to secure the sides and shoulders.

Detailed with more worbla and foam.

[Aurelius]

Bracers

used 12mm foam heat formed and shaped.
Details with more foam and googly eyes for rivets.
Bone saw was going to be moving but the motor of the toy I was going to use ended up being to big and I got frustrated with the braced and opted for something a bit more simple.
Layered foam and worbla for the blade itself.

[Aurelius]

Erratic details update.

Painted shins


Painted shoes. Had to remove the top panels because of the contact with the hin making it pretty hard for me to walk and it also squeaked.


Completed shoulders.
More or less a sort of squashed circle with some wedges cut out of it to enforce the curve at the top, all the detailing done in foam with googly eye rivets.


Painted headdress icon.
Worbla and foam with split pins. Painted with enamel paint.

[Aurelius]

Hood and mask.
Got my housemate to wrap my head in cling wrap and and masking tape. Glad I have awesome housemates.
Made the final out of wet look spandex which my sewing machine hated so I don't think I will be sewing it again any time soon.





Mask made from foam roughly based on the pepakura space marine helmet file. I do mean it when I say ROUGHLY.
Detailing with googly eyes, 25mm conduit, elastic, 1400gsm kraft card, black tulle.
There's elastic running through the conduit to hold it to the back of my head with another back going over the top which also has velcro to secure the headdress.

[Aurelius]

Test wears

[BojanK]

Epic!