Masks

I've decided to make our masks, so here's a series of pics showing how I did It...

BFG rail/frame

I thought the gun would look cool and more futuristic with a crazy frame/cage thing on the outside, so I had to figure out how to make it. I decided I'd use wooden dowel, with wood epoxy to hold it together, then mount it on the gun. 

  The first thing I had to do was make a template based off of measurements of the gun. I just bent a piece of wire to the shape I wanted, and then transferred that to paper. 

Then I taped that to a piece of wood to use as a template. 

I drilled the support pieces, and screwed them down. That way I could get exact measurements for all of the pieces. 

  I had to radius the ends of the dowels to fit, so I made a jig out of a piece of hardwood, and put it on the drill press. 

  Once all of the pieces were cut, I used wood epoxy to glue them in place. 

After it was all glued & sanded, I applied a coat of primer.

Chest armor

I decided to make some chest armor using the "foam mat" approach. I've seen some pretty amazing stuff made using foam floor mats, so I decided to give it a try.

First I started be cutting out some templates.

once I did that, I heated the areas I wanted to bend with a heat gun, & held them in the shape I wanted.

Then I cut out some accent panels and glued them on with a hot melt glue gun.

Pretty cool, huh?

I used Velcro, nylon straps, & buckles to hold it all together.

Fits great...

BFG

This year I decided to make a big f'n gun to go with my costume, so I started with a sweet nerf gun I purchased on eBay.

It had a removable front section that I'm going to relocate to the bottom of the gun.

I decided to cut some bits out to make the sections fit together. I did this with my band saw & Dremel tool.

I'm going to have to cut some pieces of plastic to fill the gaps & give me a surface to epoxy to.

I took the gun pieces apart & took all of the parts out for paint.

These are the extra plastic pieces I made out a material called sintra plastic. Good material. It cuts easy, & can be shaped with heat.

The first thing I had to do was to get everything in primer...

Ah yes, much better!

After Spraying a base coat of hammered metal finish, I then masked the gun and painted the remaining areas with a gloss black.

Lookin' pretty sweet!

Now that everything is painted, it's time to epoxy it all together!

Lookin' cool!

Now it's time to build the crazy rail/frame for it.