I've been working on both a Soldier 76 and Reaper costume
Soldier 76:

Soldier starts as a 3D print in 4 pieces.

Glue together and a layer of Rustoleum filler primer.

Bondo, sanding and smoothing. Fresh coat of primer here.

almost ready for paint

Paint. I used a mix of colors to get his mask color. Ears are black, blue is a nice cobalt blue. The gray is a mix of two colors, a dark gray and a metallic black lightly sprayed overtop.

Strap installed. Used epoxy sculpt to install two clips on the inside to loop the strap though. The strap is from a pair of swimming goggles. When my hair is white for the costume, it will be hard to see. The clear strap is great and is secure on my head.

visor and lights installed. I can see fine, its just red. The light is El wire, and sits right above my eye line. There is no light bleed so my vision is great. The actual visor is a film gel used for reading and what not. Its a bit thinner material than I'd like, but once its glued in, and the el wire place behind it, its not moving any where.

The wire will be hidden under my balaclava when I wear it for the full costume, and the battery pack in one of the pouches on my shoulder.
Here's a Gif of the lights
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My Reaper mask

Same as above. 3D printed piece. Several parts, glued together with super glue, cleaned with Filler primer and bondo spot putty.
Here is the mask ready for paint.
Original Reaper model by: Salomaoric
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Up next:
Soldier 76's gun, and Reaper's Guns. Stay tuned
Soldier 76:

Soldier starts as a 3D print in 4 pieces.

Glue together and a layer of Rustoleum filler primer.

Bondo, sanding and smoothing. Fresh coat of primer here.

almost ready for paint

Paint. I used a mix of colors to get his mask color. Ears are black, blue is a nice cobalt blue. The gray is a mix of two colors, a dark gray and a metallic black lightly sprayed overtop.

Strap installed. Used epoxy sculpt to install two clips on the inside to loop the strap though. The strap is from a pair of swimming goggles. When my hair is white for the costume, it will be hard to see. The clear strap is great and is secure on my head.

visor and lights installed. I can see fine, its just red. The light is El wire, and sits right above my eye line. There is no light bleed so my vision is great. The actual visor is a film gel used for reading and what not. Its a bit thinner material than I'd like, but once its glued in, and the el wire place behind it, its not moving any where.

The wire will be hidden under my balaclava when I wear it for the full costume, and the battery pack in one of the pouches on my shoulder.
Here's a Gif of the lights
--------------------------------------------------------------------------------------
My Reaper mask

Same as above. 3D printed piece. Several parts, glued together with super glue, cleaned with Filler primer and bondo spot putty.
Here is the mask ready for paint.
Original Reaper model by: Salomaoric


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Up next:
Soldier 76's gun, and Reaper's Guns. Stay tuned