Spider-man 3 Symbiote Suit

I had started building this suit for Halloween the year Spider-man 3 came out in theaters back in 2007. I had every plan of finishing it before Halloween, but I was having issues with the urethane rubber for the webbing not setting up correctly because of moisture in the air. I ended up scrapping the costume for a few years, but eventually came back to it in 2010. I'm actually kinda glad I had put it off for those years because I learned a lot more about the different types of materials and tricks working with them.

Everything on this suit is custom made. Nothing was bought other than raw materials. The fabric for the suit was a 4 way stretch "wet look" charcoal grey lycra from www.spandexworld.com. I needed up going with the charcoal grey even though the suit is black in the movie because I was going to add a black brick pattern over top of the grey lycra. To achieve this I designed a pattern in Adobe Illustrator that was the same as the pattern used in the movie.

I then had this pattern cut in sheets of vinyl and applied it to the top of the grey lycra. Once all the vinyl was applied I used a black fabric spray paint called Design Masters and sprayed over top of the entire fabric. Once the paint was fully dried I pulled the thousands of little vinyl stickers off revealing the new patterned material. This is NOT how it was done in the movie, but it was what I had access to at the time.

The next step was to have the material cut and sewn to the same pattern as they used in the movie. The reasoning for this is because the urethane webs are applied on top of the seems, making the suit look seem-less. I ended up buying a red/blue suit pattern off of eBay at the time that I used for the pattern. Unfortunately I dont have any pictures of the pieces laid out in pattern form.

On to the urethane webs! Along with the original suit pattern I bought, it also had the web pattern on it as well. In Adobe Illustrator I removed the webs from the original file and made them their own file which I could use later to have web molds made.

I decided to use Smooth-On's ReoFlex 30 urethane for the webs which would be strong enough and flexible enough to stretch with the suit once it was glued in place. Unfortunately the urethane is beige in color and I wanted them to be black. I tried adding color tint to the rubber, but it only weakened it because of how thin the webs are. I finally settled on using fabric dye to dye the finished cast webs. Once the webs were dyed and dried, they were coated with graphite to give then the shine like in the movie.

 

Many test fits were done to ensure the webs would fit correctly on the suit before anything was glued down. In this picture you can see the brick pattern very clear on my hand and the shine of the webs from the graphite.

So once all the webs were cast and coated, I wanted to make the eye lenses before I started gluing everything down. For this I also made an Adobe Illustrator template that I would used to later sculpt the lenses.

A mold was then made from the sculpted pieces and the final frames were cast in black urethane plastic. The inside lens was made from thin PETG plastic and painted screen mesh from a cooking splatter screen.

On the movie suit the eyes were not permanently attached to the mask they clipped onto a face shell that was under the mask, so that is how I wanted my suit to be. I ended up making a fiberglass buck for a vacuum table and heated ABS plastic over top of it.

Now with all the parts manufactured I could start the final assembly.

Many objects were used in the final assembly of the suit. A duct tape dummy was made of myself to correctly fit the webs on the suit. I also had a friend that was my same height and build wear the suit so I could position the webs correctly. A fiberglass mannequin and a life size human head bust were also used.

 

All the webs were glued down with Loctite Super Glue Gel. The great thing about super glue gel is that is sits on the fabric as opposed to seeping into the fabric.

 

There was a lot to this suit and I just kind of gave you all a brief "how to" of how this suit was made. So if you have any questions feel free to ask as I will answer them the best I can.

Spider-man 1 Pumpkin Bomb

Back in 2006 I had this crazy idea that I wanted to build a replica of the Spider-man the movie pumpkin bomb that the Green Goblin uses. At the time I had no clue how I was going to build it. I first started with a glass ornament Christmas ball, and soon realized it is way too difficult to cut glass perfectly. So the alternative was to laser cut 1/16 acrylic pieces and heat bend them onto a glass ornament ball to give them the correct same. Once I had all the pieces I needed, I painted them with a 4 stage paint process and assembled it all on to a plastic ornament ball. I also laser cut a base/stand to make it look like spiderweb holding the pumpkin bomb up.

In 2011, for the Phoenix Comicon show I placed the pumpkin bomb into an old glass clock display case and lit it with green LEDs. Here is a picture walk through of how it all went down.

 

 

Props and Costumes

Because we are getting closer to Phoenix Comicon 2012, I thought I would post up some of my previous prop and costume builds from years past before I had a blog to post them on. Ill be doing one blog a day on a different prop or costume each day up until the con. Since I wont have a table there this year I though this would be a good way to show off some of my collection.

First up, my first prop ever built. It is Darth Vader's lightsaber from Return of the Jedi. It is all hardware built from a sink tube,a trailer hitch cover used to make the hilt and many other random parts. This is about as accurate as you can get other than owning the real deal. And as it stands its the only Star Wars prop I have ever built.

Ray Gun Redesign

From the beginning, the makers of Voyage Trekkers wanted to have a unique ray gun for their series. Unfortunately do to time constraints when filming season 1 there was not a lot of time to spend on making custom weapons. Now that season 2 is in production the creator/director and the head of the art department came to me to redesign the ray gun from season 1. The ray gun from season 1 was basically a nerf gun repainted. My job was to improve upon the current ray gun, making it more unique to the series. This is the build up to that gun.


Original unmodified Nerf gun. Same model used in season 1.

These are all the parts I will use from the original gun.

With a Dremel tool I cut off parts of the handle and pieces of the main body.

Then I cut a strip of 1/16 ABS plastic and super glued it in place of where the handle was cut.

Next step is to fill all the gaps and unwanted areas with epoxy putty.

Once the epoxy putty was completely dry I added a thin layer of filler over all those areas to smooth everything out.

Once the filler is sanded smooth, the body of the gun is sprayed with a coat of primer.

Next step was to mark the cut in the trigger and drill it out.

Certain found objects used in this build had to be molded because of only have one available (3 guns were to be made) or because I needed them cast in a different material than what the found part came in.

Inner part of the body was cast in clear so it could be lit with LEDs.

PVC tubes were cut and mounted under the barrel of the gun.

Automotive wiped blades were cut up and used as fins and other details on the ray run.

3 coats of automotive grade white paint applied.

Black parts hand painted in and entire body clear coated.

Once the paint was fully cured the entire gun was assembled and the custom LED wiring placed inside. Here is a look at the season 1 ray gun compared to the season 2 ray gun.