Borderland Psycho - WIP

Greetings, all. I've been a lurker of the 405th for a few years now and, after many failed starts, have finally put some effort into a real costume. I opted for a Bandit Psycho from Borderlands after I realized I was being far too ambitious with my previous projects. In any case, with some real work done, and the end in sight, I thought I'd share this project with everyone else.

For reference check this out.

While not my first attempt at pepakura, this is the first time I managed to stick with it beyond applying resin, so if you've anything to recommend that would make the project easier or produce a better result feel free to let me know.

I started as I imagine most projects start, with a printer and some card stock; this is definitely my favorite part. I used a drop of super glue to secure the tabs, for which I used a ruler and a couple of ball-point pens to get nice and sharp, though it occurred to me afterward that that may not have been the best plan as it just meant more sanding of a piece that was designed to be rounded.




After the pep was done it was off to the store for fibreglassing supplies!



I applied a total of three coats of fibreglassing resin on to the paper, both inside and outside for structural integrity.



I figured now was a good time for a test-fit before I made too much progress in the wrong direction. Luckily it fits pretty darn well.



My intent was to apply a layer of rondo (I used a 50/50 blend of bondo body filler and bondo fibreglassing resin, as seems to be the accepted ratio around the internet, with an appropriate amount of resin hardener), then do another layer of rondo and fibreglass. After the first layer, however, I discovered how heavy it was really going to be, and how tough it was already, and decided to forgo the fibreglass for pure rondo. It turned out to be just fine that way.




With that part complete it was time for some sanding to get things a bit more even and certainly less angular. I threw down a coat of grey primer before getting started to try and highlight the areas I should focus on.



I did all of my sanding my hand, occasionally with a foam sanding block, beginning with a 60 grit and moving through a 220 grit sandpaper. It's very smooth, I've decided to stretch a piece of cloth over the face, however, so a fair amount of my sanding was for naught.




With the basic shape taking form I moved on to spreading some bondo into low points to fill in some of the protuberances, as well as to achieve greater symmetry, followed my a little glazing putty to get the last of the pin holes.




I'm not sure if I should have done this part earlier, but I didn't want to have to apply rondo around the holes so I waited to cut then out until this point. I removed these sections with a borrowed rotary tool and it made life much more simple; I'll definitely be purchasing one before my next project.



Some grey primer to give me a better look at its current state.



That's it for now, but I'll be finishing it this week, as I have to have it ready for Freak Night 2011 (WARNING: The website will play music!). I'll leave you with a parting hint of the rest of the ensemble, but keep an eye out for the rest of the build in the next couple of weeks.

Wow, very nice job on the mask. I cant wait to see how the painting goes, as well as the rest of the costume!

I like it, very nice job!

Thanks, guys! Made a run to the store today and picked up the remainder of the items for the goggles and respirator, as well as a couple of items to round out the rest of the get up. Nothing like progress as a motivation to finish.

A short update since I've gotten a little accomplished this evening. I applied some off-white linen to the mask to give it some texture as the painted versions I've seen weren't really to my liking.



I also put some faux-leather on at the seams.



I'll be continuing on into the evening with the strapping to attach the mask to my head as well as the fan, I'll try and get some pics up before bed.

EDIT:

Finished the lower half. I used some 4mm eva foam to make the metal bits on the chin, and a few dots of hot glue to mimic rivets in the corners. I used the same method to produce an o-ring around the respirator. To create the fan I simply cut the fins off of a computer fan and hot-glued them together in the center. I filed the edges down to make the whole thing a circle small enough to fit into the opening I created. A dab of stainless steel spray paint finished it up.



I thought the metal looked too clean so I gave all of the metal pieces an ink-wash to give it a little more depth. Which do you prefer?



Still working out the strapping, trying to decide if I want to drill a hole and screw the things into place.

I wanted to make one of these before my mkvi, before i knew about the 405th... Soo seeing this is exciting
It's looking AWESOME soo far, Did you think about destroying a computer case fan, painting it rust brown/red, then a coat of chrome, then some scratching.

Went and got my borderlands case and yeah, the outside blades are too numerous and close together to make with a case fan...
But an old valve re-seater would go nicely in the center and painted silver, or even polished. It's hard to make out what the outside blades are made of from this photo, looks like cut up tin can..

Dude i'm an idiot, i read your post again and just realised how dumb i sound -.-'

Mannn that's looking awesome, borderlands 2 is comfirmed too !!!

great work with the cloth; it creates a really nice texture! Cant wait to see this finished

i think what you were able to do with the different cloth layers is definitely going to make the mask stand out as GREAT!

I am impressed with this so far. It is looking good, I like the different materials you are using and I think it will give it a great look when finished. I also have to say the pepping looked like it would be tedious with all the angled faces on it. You did a good clean job on that.

I do have 1 question however. You said you used a 50/50 rhondo mixture. is that all you used for support and stiffness? Also is that as sturdy as resin and cloth for structure?

Wow. Thanks everyone. I've not done a lot of work like this so I appreciate your sentiment.

It's looking AWESOME soo far, Did you think about destroying a computer case fan, painting it rust brown/red, then a coat of chrome, then some scratching.

Click to expand...

I did, in fact, use a computer fan, though I probably could have tried to find one that was more suitable. Either the hole was too small or the fan was too large, so I made do. I'm psyched for Borderlands 2!

You said you used a 50/50 rhondo mixture. is that all you used for support and stiffness? Also is that as sturdy as resin and cloth for structure?

Click to expand...

I did an initial coating of just fiberglassing resin, but after that it was simply a few layers of rondo. The final product is about 1/4" thick. In the future I don't know that I'll go quite as heavy, the mask is pretty sturdy. If I were doing a different piece, something large or carrying a lot of weight, I'd think twice about the method I used here, but all in all I'm confident it's tough enough to withstand wearing while dancing.

On a final note I finished this evening! Hooray! I have a good feeling of accomplishment. I can't wait to put on the rest of the costume tomorrow and get some pics.

I came back hoping for progress pics to your complete outfit...
Im eagerly awaiting to see it ...

Apologies for the delay. Crazy weekend! I'll try to get some of the pics of the final(ish) costume up, but in the meantime I've got this one for you.

Awesome man!!
You will have to do one of their hatchet machetes and some fake blood.

Yeah, there's definitely some things I intend to change. The whole get up is far too clean. I also want to get a glove for my right hand, as well as a drop leg knife sheath for my left leg. I'm pleased with what I wore, and being recognized was a lot of fun, but I'd like to make it more accurate. Thanks for the praise, I definitely intend to put together a buzz axe in time for a local con this winter.

Awesome job man. You did a great job putting everything together.

What a sweet costume! Borderlands is one of my favorite games (besides halo but still). Quick question, where did you get the pep file?

That's pretty sick looking dude. I'm diggin' it.