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Caboose


Year Completed: In progress
Made By: Cadet
Click here to view the full Caboose costume gallery
Click Here to view the full progress gallery
Description
The Mark V MJOLNIR armor from Halo, painted up in "regulation" blue, with a special bullet hole in the left pinky toe, in order to match the look of the Character Caboose from the popular Web series Red vs Blue, form the show's second season.

This costume was made using the Pepakura method. Pepakura is a piece of software that can break down 3-D models into flat surfaces, which can then be printed, and reassembled into the original 3-D shape. This software is intended to be used in the art of paper craft, or folding paper to make small models, like a more detailed version of origami. In recent years people have begun to put life size models into the program and use it recreate costumes and props.
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Paper print out 1
Here is the raw pepakura print out, prior to cutting, folding and assembly.
Paper print out 2
Another view of the the pepakura print out.
Helmet progress
The helmet in mid-assembly
Shoulders and Forearm progress
The assembled shoulders and forearms before fiberglassing
Helmet Assembled
The fully assembled helmet, prior to fiberglassing. If you note, the internal support structure in the visor area is still in place. It is very important to leave the pep model supports in place until after fiberglassing, to prevent the model from wrapping.
Fiberglassing the Helmet
A layer of straight resin is applied to the outside of the model. After which fiberglass matte or cloth, depending on your preference is applied on the interior of the model. resin is then applied to the fiberglass and allowed to soak in, which when dries becomes very rigid and stable.
Adding some mud
As part of the smoothing process, bondo type automotive body filler is typically applied to the exterior of the fiberglassed pieces. In this case, a mixture of 1 to 1 bondo and resin was mixed together with a little of the bondo hardener and the hardener for the resin. The result is much more liquid than regular bondo, and can be poured, often resulting in a smoother finish.
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Link from Legend of Zelda | Umbrella Corporation Security Services