Alias Cosplay

Costume :Sarah Kerrigan
Variant :Ghost Armour
Source :StarCraft
Progress :Complete
Worn At :Kitacon IV (2012)

Costume Photos

Ghost Armour, StarCraft


Sarah Kerrigan

Kerrigan, Ghost Armour

Kerrigan, MCM Expo

This is Kerrigan....

Ghost Armour, StarCraft

Ghost Armour

Sarah Kerrigan, StarCraft

Kerrigan, Expo

Kerrigan, StarCraft

Kerrigan, London Expo


Costume Information

Awards : 3rd Place, Kita 4

My first costume that involves armour making.
Paired with Leadmill as Matt Horner.


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This will be all kinds of awesome!

by Leadmill on Sunday, 1 May, 2011 - 17:07
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I've been waiting to see someone do this for a long time!

Good luck!

by Numta on Wednesday, 4 May, 2011 - 11:06
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niiiice ^^

by nanahara on Sunday, 5 June, 2011 - 15:13
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this is looking stunning, i can see this being reallllllly effin amazing. Hope i get a chance to see this in person

by isamiaella on Wednesday, 8 June, 2011 - 17:44
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This is looking REALLY awesome so far hun!

by sjbonnar on Thursday, 9 June, 2011 - 06:41
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Wow, I'm really looking forward to seeing this finished, the progress looks brilliant!

by RevolverKitty on Thursday, 9 June, 2011 - 16:04
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I can't believe how badass that headset looks already!

by sjbonnar on Tuesday, 28 June, 2011 - 07:47
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This is looking epic already.

by Leadmill on Saturday, 6 August, 2011 - 19:21
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More StarCraft love - its nice to see. ^_^
Its interesting how were all going slightly different routes to make SC Ghost suits. I keep popping in to see you are getting on. Youre making great progress. I like your idea of doubling up on the body suit fabric, I never thought of trying that. My white lycra is very thin - and this could be how to get the thickness I am after, hope you dont mind if I try this out on mine. :)

by Ranma1-2 on Saturday, 6 August, 2011 - 22:07
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I had to double up on the fabric to prevent underwear being seen underneath, plus it feels more secure having that extra layer and sure try it out :)

by Alias Cosplay on Sunday, 7 August, 2011 - 09:43
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Nice progress, the two tone really makes the bodysuit. :)

by Ranma1-2 on Saturday, 13 August, 2011 - 19:54
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This looks amazing so far, I cant wait to see it all completed and being worn :)

by Yasmia on Saturday, 27 August, 2011 - 22:51
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Absolutely fantastic. ^_^

by RebaSephiroth2 on Sunday, 4 September, 2011 - 13:38
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Epic Cosplay Progress is Epic!

by Leadmill on Tuesday, 13 September, 2011 - 17:45
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The longshot looks fantastic! as does the suit!

by Captain_Marvelous on Saturday, 1 October, 2011 - 16:33
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by GAINAX on Saturday, 1 October, 2011 - 18:10
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C-20 looks ace. :)

by Ranma1-2 on Saturday, 1 October, 2011 - 21:28
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This is just awesome!

by Leadmill on Saturday, 1 October, 2011 - 21:54
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Looks awesome! I especially like the the sniper rifle. Great job!

by Kata-san on Monday, 3 October, 2011 - 18:42
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I hadn't seen any of this so far, it was really nice to go through the journal and see your progress. Some lovely, really detailed work here, I hope you have fun with the rest of the costume.

by KhaosKreator on Tuesday, 4 October, 2011 - 10:44
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Looking good! Looking really good! God I wish I had artanis for this!

by Manticore on Wednesday, 26 October, 2011 - 22:54
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Lookin hawt! well done hun! its already extremely impressive and it isnt even finished!

by Captain_Marvelous on Saturday, 26 November, 2011 - 15:23
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Simply amazing, you are going to look stunning. Each update is even more amazing than the last!

by Leadmill on Saturday, 26 November, 2011 - 20:06
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Finished hip guards - wow they look really cool.

by Ranma1-2 on Saturday, 26 November, 2011 - 22:42

This is looking so very awesome! I can't wait to see it complete!

by goodbyeworld on Wednesday, 30 November, 2011 - 22:05
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Bloody hell hun, is there anything you can't make?! This looks AMAZING! Would I be able to get some video footage of you at Kitacon please?

by Littlegeeky on Saturday, 3 December, 2011 - 11:41
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Looking amazing as usual!

by Leadmill on Saturday, 3 December, 2011 - 14:32
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Crud, your cosplay detail is amazing sweety...and it's not even finished. O.O!

by Mangamad on Saturday, 10 December, 2011 - 11:02
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Simply fantastic, a brilliant demonstration of your skills!

by Leadmill on Saturday, 24 December, 2011 - 13:49
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Jesus Christ O_O Every time I think your skills have amazed me, you take it a step further O_O

by sjbonnar on Monday, 26 December, 2011 - 04:57
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by Leadmill on Saturday, 7 January, 2012 - 14:41
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Wouldn't be able to tell this is your first time armour-making; you're doing a fantastic job of this. Not a Starcraft fan, but looking forward to seeing the finished costume.

by Quinzel on Sunday, 8 January, 2012 - 06:15
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This is really looking like something special, great to watch it all come together in detail like this.
I also love that you're using neon coloured foam as every update looks like a crazy 1960s space show costume :D

by Amy-Lou on Sunday, 8 January, 2012 - 12:20
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Soooo awesome!

by ToroSonyCat on Sunday, 8 January, 2012 - 12:56
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seriously, this is looking so amazing XD

by nanahara on Sunday, 8 January, 2012 - 12:59
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This looks very cool and very well made :)

by Siouxsie James on Sunday, 8 January, 2012 - 16:27
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Looking great! Weird question but where did you get the clear plastic domes for the chest piece? I'm always stumped for where to find them. I remember for my Siegfried sword I used 2 poundland fake security cameras because I couldn't find anything else!

by KhaosKreator on Tuesday, 10 January, 2012 - 09:25
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Thanks everyone, and Tab - they're clear acrylic spheres found on ebay and

by Alias Cosplay on Tuesday, 10 January, 2012 - 17:45
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Looking brilliant!

by Leadmill on Sunday, 22 January, 2012 - 17:01
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This is looking absolutely amazing! Really can't wait to see it finished. :D

by Alinthia on Tuesday, 24 January, 2012 - 15:51
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Amazing cosplay is Amazing! Well done!

by HatsuneHawke on Saturday, 28 January, 2012 - 14:07
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by nanahara on Saturday, 28 January, 2012 - 17:10
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The level of detail in this is incredible.

by Nomes on Saturday, 28 January, 2012 - 17:36
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by Kacela on Saturday, 28 January, 2012 - 17:46
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by sjbonnar on Thursday, 9 February, 2012 - 18:39
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You are doing a fantastic job with this, i'm completely in awe!!

by Alyx on Saturday, 11 February, 2012 - 23:15
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this is looking awesome

by Defrain on Sunday, 12 February, 2012 - 13:07
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Very very impressed by your amazing progress! The finished thing is going to look so amazing

by Fables on Sunday, 12 February, 2012 - 14:51
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I don't think I can geek out enough over Kerrigan! Well done!

by Manticore on Friday, 24 February, 2012 - 18:07
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Epic win!

by Leadmill on Friday, 2 March, 2012 - 14:21
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Holy hell you my freind are amazing.. ive never played starcraft myself but this cosplay is Fantastic

by Ruxtano on Sunday, 11 March, 2012 - 18:13
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Neat solution to the wig styling, thanks for sharing. :)

by Ranma1-2 on Sunday, 11 March, 2012 - 22:47
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In the infamous words of Johnny Bravo: "Woah, momma!". Amazing work and frankly this is hot!

by WarriorTeddy on Tuesday, 13 March, 2012 - 17:38
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Oh my gosh this is so badass!..I Love it ^_^ Storming ahead with this.

by Ranma1-2 on Tuesday, 13 March, 2012 - 23:50
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Seriously, every new thing seems to amaze me even more!

by sjbonnar on Thursday, 15 March, 2012 - 14:25
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Wow! Simply Amazing!!

by Zelda on Saturday, 17 March, 2012 - 13:58
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soooooooooooo EPIC XD

by nanahara on Saturday, 17 March, 2012 - 17:47
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Outstanding! Ive been following this for quite some time. The level of detail and the amount of time you have put into this is inspiring. This is an example to all of how realistically armour can be made with foam.

by Nomes on Saturday, 17 March, 2012 - 20:44
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this looks so good the detail is amazing

by lycaneyes on Sunday, 18 March, 2012 - 01:16
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Looks fantastic ^_^ Can't wait to see it all with the lights on in person ^_^

by Zelvyne on Sunday, 18 March, 2012 - 11:54
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by Leadmill on Sunday, 18 March, 2012 - 12:02
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awesome !

by kojima on Friday, 23 March, 2012 - 15:09

This costume is just epic. Is it sad that my favourite part of it was the tiny skull on your (left?) shoulder? lol. Congratualtions on winning at the cosplay competition. It was really lovely to chat with you and your friend briefly before the masquearde (I was the grey one in red leather). Well done because this costume is just fabulous. :D

by Pudding on Tuesday, 17 April, 2012 - 15:26
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Oh wow, this looks so awesome :D

by Sillabub on Tuesday, 17 April, 2012 - 17:23
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This was amazing IRL!

by Leadmill on Tuesday, 17 April, 2012 - 22:44
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This was great to see, an amazing piece. Hopefully get a picture the next time you wear it (Curse my dead memory card!)

by MattDark on Thursday, 19 April, 2012 - 11:23
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It was great to talk to you backstage love, you looked amazing! I hope to see you again soon ^_^

by Manticore on Thursday, 19 April, 2012 - 20:33
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This is brilliant. All kinds of epic. Love the armour. Great job on it. Well done on the award ^^

by Sephirayne on Thursday, 19 April, 2012 - 20:49
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You looked amazing and you worked so hard on it, You deserved first place in my opinion. Really impressive for first time with armour!

by Saffron on Friday, 20 April, 2012 - 00:57
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Really nice work here - for a first armour project it's particularly impressive!

by Mighty Odango on Friday, 20 April, 2012 - 07:25
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Thank you everyone.

by Alias Cosplay on Friday, 20 April, 2012 - 15:18
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as has been said before this was amazing to see you and i think you deserved first place =P

by Numta on Friday, 20 April, 2012 - 15:18
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So cool I had to walk up and tell you so at Kita when I saw you standing in the corridor. This very much deserved to win an award in the cosplay competition.

by Nomes on Friday, 20 April, 2012 - 18:01
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This costume was amazing, even if we shared to kitacon cosplay discomfort. Have you got any ideas on how you're going to mod to make it more comfortable?

by Manjou on Friday, 20 April, 2012 - 18:40
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Thanks again. Not as yet but will have to revise some things, I hadn't expected on wearing it for long periods but as you know there were delays.

by Alias Cosplay on Friday, 20 April, 2012 - 19:06
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I run out of convincingly amazing things to say about your costume but this one was particulaly of note!

by Captain_Marvelous on Friday, 20 April, 2012 - 19:21
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amazing job! i am gutted i didnt get to see this at Kitacon, i was especially looking out for it as well.

by Leolarua on Saturday, 21 April, 2012 - 12:03
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So cool!

by CharlotteLuna on Saturday, 21 April, 2012 - 23:57
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Your cosplay looks Fabulous! Was walking difficult in the leg armour?

by Ranma1-2 on Sunday, 22 April, 2012 - 14:21
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I had expected it to be but it wasn't bad at all, steps were a little be tricky.

by Alias Cosplay on Sunday, 22 April, 2012 - 14:23
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Hmm Im worried about constricted movement in leg armour..
I hope I get to see this irl at an Expo sometime. :)

by Ranma1-2 on Sunday, 22 April, 2012 - 14:45
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I wish i had your skills... this is beyond epic!

by Fishyfins on Monday, 23 April, 2012 - 23:21
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Turned out even better than anticipated and that's saying something. Utterly incredible!

by sjbonnar on Wednesday, 25 April, 2012 - 10:32
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Been keeping an eye of this and loved it when I saw it at Expo. Good job. If you do ever recall where you got the fabric from will you let me know?

by theKillingDoll on Wednesday, 30 May, 2012 - 16:07
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Thanks and its been awhile but I will have a look if I still have the link for the fabric.

by Alias Cosplay on Wednesday, 30 May, 2012 - 16:15
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Although i'm not too familiar with the game I just love this!
So much attention to detail, your skills continue to amaze me =)

by Moonchild on Thursday, 31 May, 2012 - 21:15
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Your Kerrigan is by far my favourite project, a jaw droppingly intricate job.

by Leadmill on Thursday, 31 May, 2012 - 23:26
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So good to see this irl, you did a fantastic job on it..Cannister rifle looks awesome too :) Really nice chatting with you and Leadmill in the masq queue.

by Ranma1-2 on Saturday, 2 June, 2012 - 12:02
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This was awesome. I was glad to see it in person at MCM, even though it was in the queue for the masquerade. It looked great!

by Kata-san on Monday, 4 June, 2012 - 14:27
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This is so impressive, I'd love to see it up close - it looks so neatly made. I really enjoyed looking through your journal entries and love the photos with the lights showing up.

by Angelphie on Saturday, 25 August, 2012 - 10:00
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Thanks Angela and everyone else for the nice comments.

by Alias Cosplay on Saturday, 25 August, 2012 - 17:45

Congratulations on the show case. So well deserved.

by cannibalistic_cow on Sunday, 7 April, 2013 - 16:36
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Grats on the showcase!! :)

by Siouxsie James on Sunday, 7 April, 2013 - 17:11
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Congratulations on the showcase, well deserved :D

by Manjou on Sunday, 7 April, 2013 - 18:58
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Happy to see this showcased. Very well deserved ^_^

by Sephirayne on Sunday, 7 April, 2013 - 20:30
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this is BRILLIANT and well deserving of the showcase. i'm currently working on 2 cosplays that involve alot of foam armour and your stuff has been an inspiration and really interesting. FANTASTIC XXX

by loramarsden on Monday, 8 April, 2013 - 08:22
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All your cosplays are so amazing hun! I dream of having talent like this!
Congratulations on the showcase hun! Defiently well deserved!

by Littlegeeky on Monday, 8 April, 2013 - 10:32
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YESSSSSSSSSS!!!!! perfect! gratz on showcase, well deserved :3

by Fishyfins on Monday, 8 April, 2013 - 18:34
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Congrats on the showcase! Very well deserved :)

by Freyarule on Tuesday, 9 April, 2013 - 10:19
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Thanks everyone!

by Alias Cosplay on Wednesday, 10 April, 2013 - 16:29
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Oh wow this looks fantastic, and loved going through the journal! Congrats on the showcase :)

by alytheluvly on Friday, 12 April, 2013 - 08:20
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Great costume - so much detail on the armour and it lights up too! It was interesting reading your journal and seeing how the costume was developed

by ArcaneArchery on Saturday, 13 April, 2013 - 20:09
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Congrats on the showcase hun!! :D

by Manga Girl on Friday, 3 May, 2013 - 14:29

To-Do List

White + silver grey jersey stretch fabric (textured)MediumComplete
Boot and leg armourLowComplete
Thigh armourLowComplete
Wig, contact lenses and make up testLowComplete
Head set/gogglesLowComplete
Pattern for bodysuitLowComplete
C-20A rifleLowComplete
Main chest pieceLowComplete
Armour light source: EL disc, LED's, EL stripsLowComplete


Final test (Posted 17th March 2012)

Final test of the suit with all of the armour pieces, the best I could do without assistance. The wires at the back will need to be pushed under the chest pieces to hide them and the pauldrons put into place a little better. Also the goggles will need to be connected to the main piece with help.
The thigh pieces were quite snug in the first place but a velcro strip was still used in the inside to stop them moving down. They rest just above the knee cap. I painted the suit a darker grey around the knee area instead of using a separate knee support because it reduced flexibility around the joint.
Going to save switching on all of the LED's for the con :)

Gauntlets and gloves (Posted 15th March 2012)

Tested the gauntlets and gloves worn together, added a little more detail to the gloves around the thumb and sides.

Thigh armour (Posted 13th March 2012)

Added the detail and some armour weathering, these will fit above the knee. They are a whole piece and slip up my leg into place, leaving enough give for flexibility. As predicted the knee supports were too restricting over the already tight fitting suit and underneath the leg armour, so I'll be making my own from the same stretch grey fabric I used for the catsuit. These will fill in the area between the leg and these thigh pieces.

Gauntlets (Posted 13th March 2012)

Added detail and armour weathering, fixed the top piece with the tinted acetate to the main section and sealed with latex. There's a area underneath for the LED to fit snugly into and they fasten with velcro underneath. Top is for my right and bottom for my left arm. Will be testing them against the gloves next.

Hair tie and ponytail. (Posted 11th March 2012)

Hair tie made from thin foam and attached with velcro around the pipe cleaner that gives support to the ponytail base. I bought two long wigs, trimming the first pinning the ends into the nape of the nack and then attaching wefts from the second to create the high ponytail. It's supported by a black pipe cleaner around the base, light enough not to pull the wig back.

Make up and contact lense test (Posted 11th March 2012)

I used light grey contact lenses in the end, make up is basic so not to clash with the wig and eyebrows were tinted red slightly with make up. Headset needed adjusting slightly and still needs the connectors attached to the end of the white wires, which will then fix to the ones on the back of the chest piece.

Gauntlet Base (Posted 11th March 2012)

As I was waiting for some more spray paint to finish the thigh pieces, I started making the arm sections. I used a paper template to get the scale right then transferred it to foam. Thick foam was used as the base with thinner pieces on top in sections. The part with the blue section was made separate since the tinted acetate sheet is easier to attach after painting the foam. These pieces will be fixed on top of the main gauntlets which fasten with velcro.

Base for thigh guards (Posted 4th March 2012)

As with all the foam parts, a paper template was drafted first and transferred to foam. The thigh pieces are made from two layers of thin foam with some detail added and sealed with latex ready for painting. I'm planning to use knee supports to hide the bodysuit at the point between the leg and thigh armour. The thigh sections are snug enough for them to stay in place above the knee whilst being comfortable and still allow movement.

Main leg pieces - complete (Posted 26th February 2012)

Finally finished these, added some armour weathering here and there and sealed them with latex. Next will be the parts above the knee, extending up the thigh.

Leg armour - LED's (Posted 24th February 2012)

The detail and weathering still needs to be added, but here's one leg piece with the tinted acetate pieces in place, the ring detail on top and the LED's fixed inside.

Leg armour - base (Posted 19th February 2012)

Using foam, I made two pieces that wrapped around the base of the boot, a piece over the front of the boot that will eventually be fixed into place and a tube for the lower leg as a base. Vertical sections of foam for the outer layer details were fixed to the base, connecting the pieces around the boot and the tube. A gap was left between these pieces to allow some flexibility and room to fasten the boots zip. The foam was heat molded at the front to keep it raised and pointed with card fixed underneath to hold the shape.
Its attached with velcro in the inside leg with a strip helping to conceal the join. I added the knee section and some detail to the foam, then cut around the top of the tube to add the shape and to make sure it didn't restrict movement at my knee. I also cut out the sections for the lights and added a section of foam to the inside knee area at the top.
I still need to create the section of armour for above the knee and the boots need finishing with a little more colour here and there.

Boots (Posted 11th February 2012)

Finally got around to darkening the boots so they will blend better with the leg armour.

Suit detail (Posted 11th February 2012)

Finally added the small sections at the front beneath the chest piece.

Pauldrons complete (Posted 11th February 2012)

Pauldrons were fixed into place using strong velcro, they still need adjusting slightly and the wiring will be pushed behind the chest piece with some help. Next to start planning the templates for the leg armour.

Pauldrons preview (Posted 7th February 2012)

Made from foam heat molded over a dome shape and thinner foam fixed on top in sections with a layer of tinted acetate sheet sealed in between. Separating the detail on top into foam sections rather than one single piece kept the heat molded shape better and made it more flexible. Added some bolt detail, some armour weathering and the small skull seen on the one side.
Added the EL tape strips in each, they will connect to the power source in the back of the main piece and velcro will attach them both to the bodysuit. I plan to turn the wiring white to help hide it better if it does show.

Chest armour complete (Posted 28th January 2012)

Finally added the details and some weathering to the front mainly and finished it off by sealing the paint with latex.

Chest armour lights (Posted 22nd January 2012)

Armour has now been painted and is ready for detail and battle weathering to be added. Photo shows the internal lights in the back, EL disc and LED. The tiny piece was added near the circle base to complete the inner section and a circle of foam was added in the centre on top of the tinted acetate sheet that covers the EL disc.

Chest piece - complete (Posted 8th January 2012)

Added all the details, including joint details, collar, tubing detail around the sides and the spine. The first image shows the basic set up for the EL disc that is seen fixed in the centre on a raised section, so that it lays flat against the blue tinted sheet of acetate that will seal the area in the centre on top. A part near the top on the back section was removed to fit the inverter that will power the EL disc and strips in the pauldrons. The main piece on the back also contains an LED near the bottom that will light up a tiny strip, a detail that will be added after painting so that it completes the circle.

Collar (Posted 7th January 2012)

I added grey fabric to the collar and a section of grey and white to the front on top of the original suit to match the reference. I added small pieces of foam shapes around the collar, painted grey with some detail and finished it with blue fabric paint on the seams.

Pauldron and back lights (Posted 4th January 2012)

The two strips of EL tape that can be cut down to fit inside the bottom edge of the pauldrons and the EL disc that will be placed in the back, all connected to an inverter hidden in the main chest piece with a 3 way splitter.

Chest pieces - base (Posted 24th December 2011)

Added thin foam to the card on inside to keep it in place when worn and thick foam on outside. Made the base for the main back piece which will have a circle of tinted blue plastic in the centre and added the small connectors around the edge, the top ones will link to the wires that come off the headset.
Will be using an inverter with a 3 way splitter, one linked to an EL disc in the centre and the other two linked to the EL strips that are going in either shoulder pad.
Need to add the final thin layer of foam on the outside of the main chest pieces that will have the detail added to it and mould the foam around the plastic domes for the chest. It attaches together at the sides with velcro. For the tubing detail on the sides I'll be using one half of foam pipe insulation.

Chest piece template (Posted 18th December 2011)

The template was made from card, this will be the base on which the foam will be fixed to, giving it a little more strength.

Suit Seams (Posted 10th December 2011)

Added the final suit seams by carefully marking them out whilst wearing the suit and the armour pieces, topstitched then made bolder with a fabric pen and added the neon blue.

Side piece (Posted 3rd December 2011)

Made in the same way as the hip pieces, using foam and velcro to attach it. I made sure to make a small indention on the one hip piece which the tip of the thigh piece slips under so that it looks like it is attached. I didn't have great ref's for this on Kerrigan's design so I used the general shape from Nova's.

Hip Guards Complete (Posted 26th November 2011)

Finished the second piece and in the end used extra strong white velcro to attach them both. I carefully matched them up then glued the velcro pieces to the suit to stop them peeling off. Next I need to mark up the final lines between the two hip pieces.

Hip Guard LED test (Posted 19th November 2011)

I primed and finished spray painting the pieces for the hips, the top one has been given some shading detail and the piece beneath it has the acetate tinted blue attached to it, ready to be glued over the main section that will hold the light source. I tested the LED's inside it and now I have to decided either to fix the pieces permanently to the suit or heat form it a little more so that it doesn't pull the fabric if velcro is used instead.

Hip Guards progress (Posted 16th November 2011)

I made many paper templates and foam templates first, measuring them against the suit and carefully judging where they should sit. I used both the Nova statue and Kerrigan video clip as refs and the designs near the bottom are the finished pieces, sealed with latex ready to be painted.
The LED's will fit inside tiny pockets I have made between the layers of foam at either end of the the oval section in the centre. They will also be accessible for repairs via an opening I have left at the top of the oval piece of the main part, that closes up when the whole things bends around my hip. The two pieces near the bottom will have the blue tinted acetate attached after painting and before fixing them on top of the main pieces.

Bodysuit detail test (Posted 13th November 2011)

I tested making the lines bolder with a fabric pen and added the bright blue fabric paint alongside. This will take some time to dry, so the suit will be painted in sections. Its the alternate to using EL wire in the suit.

C-20A complete (Posted 3rd October 2011)

Decided to add some dry brush shading using a sponge and black latex colourant, then sealed it with a thin layer of latex. The whole thing comes up to the middle of my upper arm. Fixed the wire piece into place over the top of the stock and added a small clear resin gem to the front end of the sight and a piece of acetate at the other so there was something the light would reflect off to mimic the lense.

C-20A rifle progress (Posted 1st October 2011)

Leadmill gave me his old nerf rifle used for his Magneton (Gijinka) I took it apart, mainly removing the pieces along the barrel and the sight. This meant gluing the whole barrel section back into place afterwards. Using a small hand saw I sawed pieces away from the stock and used thick foam to recreate the right shape. I added a pvc pipe to the end of the barrel with holes drilled into it beforehand. The sight is made from foam and card and the detail on the sides is thin craft foam sealed with latex before spray painting it gun metal. I also added a piece of thick metal wire that fits over the stock on the top. Undecided if I will add a little shading detail before I give it a thin layer of latex to finish it. Detailed photos will follow after that.

Main suit complete (Posted 11th September 2011)

I attached the grey section to the other side of the suit. I've thickened the few seams I've added with a fabric pen and the next step will be to do the same on all of the seams, making them darker and more prominent. Then I'll be adding the blue to the seams with bright ultraviolet fabric paint, this is the closest I can get to imitating the lights within the suit. The brightness of the ultraviolet paint remains after drying unlike normal fabric paint that the fabric soaks up and leaves it looking faded.
As I mentioned before the small sections of white detail under the chest will be added once I know where the edge of the armour will come to. The same goes for the seams across the stomach and around the top of the legs, these won't be added until I know where the hip guards will rest.

Goggles/headset (Posted 10th September 2011)

I added some detail to the original arms of the safety goggles, trimmed the ends slightly and they're still tight enough on my head to stay in place, even though they don't hook behind my ears any longer. I added an extra arm on either side of the goggles which reach down to the ear pieces. The ear pieces were originally clip on headphones with sections of foam added, coated in latex, spray painted and coated in latex again to seal it with some detail added. The wig is the base, I will be styling it into the high ponytail at a later date.

Gauntlets (Posted 4th September 2011)

I used grey gloves with a polyurethane coating in the end with a better surface to fix the foam pieces to. I coated the foam pieces in latex to prevent the foam from absorbing the spray paint and added some shading and detail and finally sealing the paint with another layer of latex before fixing them onto the gloves. The main aim was to create something that was flexible and I can still move my wrists and fingers with ease.

Boots (Posted 14th August 2011)

Boots were originally cream so I sprayed them white with leather spray.

Suit progress (Posted 13th August 2011)

Attached the grey sections on top of the white, sections were added to the sleeve before I attached it to the main suit. Added some darker seam detail near the top on both sides, the rest of the seams will be added and joined up once the other side is complete. Also the little white detail section at the front will be added once I know where the edge of the armour front will come to later on. May darken all of the seams with a fabric pen. Have experimented with fabric paint also to represent the blue electronics that run through the suit. I'm planning to create the details around the neck with a separate collar. The lights and electronics have been sourced and bought for the armour. Leadmill is lending me his Nerf N-Strike to modify. Wig has been bought, waiting to be styled.

Suit Base (Posted 6th August 2011)

For the base of the suit I used the textured white stretch fabric, double layered with a 16inch concealed zip. I've decided to add the sleeves last after I've added the grey fabic now, so the one sleeve here will be removed and the suit will be taken in here and there. The grey sections will be added directly on top of the white suit and sewn into place.

Headset detail (Posted 8th June 2011)

Added the shading around the joints to give it some more detail. Will be testing the clip on earphones with the wig once it has arrived.

Head set progress 2 (Posted 8th June 2011)

Sealed the foam with liquid latex, masked off the top of the lenses and used grey primer spray paint as a base with a layer of white primer on top and a light coating of pewter before I start adding some shading around the joints.

Glove base (Posted 8th June 2011)

Off white, textured stretch gloves to be used as the base for the foam armour pieces.

Footwear (Posted 6th June 2011)

Decided on a mid calf wedge to give me some height and I'm hoping this will also prevent the leg and foot armour from scraping on the floor and limit damage to the bottom edges. I'm not too fussed with the detail of the footwear since it will mostly be hidden.

Head set progress (Posted 5th June 2011)

I traced the main shape of the safety glasses onto paper and started breaking down the design into sections. Using the sketch I transferred it to the glasses and marked out the eye hole positions even though the head set won't be functional when pulled down. I used various scrap pieces for the lenses. Here you can see the main shapes made from foam, the top arch still needs some work and fixing into place and the final details still need to be added.

Head set base (Posted 4th June 2011)

Safety glasses and clip on ear phones will be used as the base. The glasses are wrap around ones which will help me with the final design.

Main Cuirass Base (Posted 2nd June 2011)

I created a duct tape dummy of my upper body, taping a plastic orb that separates into two domes into place on me to form the smooth shape I wanted for the armoured chest. I then carefully removed the two plastic domes from the finished duct tape dummy and repositioned them behind the duct tape to create a less prominent shape. The duct tape dummy was reinforced in the photo with paper mache which will help to support the final outer layer of craft foam.
I'm using this process instead of reinforcing with other materials such as wonderflex or cardboard for various reasons. I wanted to keep costs down and using craft foam will keep it light, not too rigid to move in and less bulky looking on my small frame.

Bodysuit fabric (Posted 7th May 2011)

Stretch jersey textured fabric in silver/grey and white.