Costume :Tessai
Variant :Rock Variant
Source :Ninja Scroll
Progress :Complete
Worn At :London MCM Expo October 2008

Costume Photos


Neo Cosplay Corner Comp

Cosplay Snap

Cosplay Snap

Tessai loves his juice

Pre Comp Tessai

Pre Comp Tessai

Tessai Masquerade

Tessai Masquerade

Tessai Masquerade

Tessai Ref


Costume Information

Cost : £200
Time Taken : two and a half months

Ninja Scroll is one of the first Manga Movies i ever watched and its never left me since and is still one of my faves...

Although a short lived character Tessai is awesome he should have had a bigger part in the movie which and i would love to bring him to life XD

I was hoping to unleash this one at Minami 14 Now this one is on the cards for Ame 08 :)

The Mask

Not many photos form this point on :(
I Have also made a cast of my head thanks to Nerts great guide and Ambers Wonderful help and patience while i panic'd with my head in cast :S

As per the guide we built up plastercine to look like Tessai and painted the ot in many layers of latex..

If you are looking to do this i have a few pointers:

The average head cast needs about 5kg of paster of pairs and roughly 500g of alginite(leaving room for error)
The slow set alginaite sets very fast :O
Do not use Hot water with alginaite as it will set instantly
Breathing through tubes isnt fun at all :(

The Body Suit

The body suit was probably the most challenging part

As tessai lays such a small part in the movie it's difficult to work from the references so ive had to wing it a fair bit and use my own artistic license..

I used the body cast from my Vegeta costume details on how to make it can be found on the costume details on cos island.

I used the same technique as making Vegeta but i was ever mindful to make it not look like i had a bunch of steaks stuck to me, so i studied the human anatomy a bit and found a few charts showing muscle groups and how they overlap and connect.

So basically this time round i added the roughly shaped foam to the suit then shaped it and layered up repeating the same again, through doing this i have a much bigger size this time as well :)

The Trousers

I used a Simplicity bely dancer pattern that Laura (Sands) had used for her samurai warriors costume, Although the pattern its sef is simple getting the overhang ploom of the bottom of the trousers right was the most challenging part of this costume lol :0

It took me and Amber about 4 days to do although i think i was being a bit too much of a perfectionist and i thank amber for her patience an help :)

and the costume is DONE

The What i had to do list:

Make a Cast of my Head (DONE)
Make Plastercine Model Of Mask (DONE)
Make Latex Mask (DONE)
Take in Long Sleeved T Shirt (DONE)
Add zip to Long Sleeved T Shirt (DONE)
Paint T Shirt in Latex (DONE)
Plan and Cut Muscle groups out of Foam (DONE)
Glue Foam to T Shirt (DONE)
Paint top coat of Latex mixed with Acrylic Paint on to Torso (DONE)
Figure out how the hell to make hands (DONE)
Make Huge boomerang Sword :) (DONE)
Make Trousers and Wraps (DONE)


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Dude, I will love you if you pull this off O_O I've NEVER seen it done and that's a right shame!

by sjbonnar on Wednesday, 31 October, 2007 - 15:34
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now i know of you insane love of all things ninja scroll excet well ninja scroll 2 but this would be a awesome cos you thinking of making it similar to the muscle suit?

by alexfratley on Sunday, 4 November, 2007 - 20:22
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Tessai FTW!

nuff said!

by HelloKitty on Monday, 5 November, 2007 - 09:30
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i'm totally looking forward to seeing this costume, also being a fellow ninja scroll fan i would like to see a whole group of bad guys/girls done ^_^

by Haynes84 on Thursday, 13 March, 2008 - 00:20
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haha isnt he the one that trys to rape the girl ambers cosing as lmao OH ok thts fine then lmao

mr rock man, lets give him a dream

mike has the sweetest dream that youve ever seen lmao

go mike

by ryaoki on Tuesday, 8 April, 2008 - 16:45
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Ahhhhhhh another costume I cant wait to see!

Ninja Scroll is ACE

by stripey_dani on Tuesday, 8 April, 2008 - 16:58
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trust you to get the wrong idea reiss

hes not a hentai tentical monster ><

by MangaChild on Tuesday, 8 April, 2008 - 21:15
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COME ON MAN YOU CAN DO IT im ruiting for you here, i fucking cant wait to see some progres your going to make an amazing tessei and be an inspiration to me again like the rest of your costumes aree, aww man thanks alot for ALL YOUR cosplay help ive REALLY gotten into it now and feel confident to work on my own i OW you something bigtime

by ryaoki on Sunday, 1 June, 2008 - 11:29
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omg sword progress is looking superb man

by ryaoki on Sunday, 1 June, 2008 - 12:52
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Where did you get the stuff you make the sword from? I need some D:
Awesome progress by the way, can't wait to see it complete 8D

by Mocha-Berrytan on Sunday, 1 June, 2008 - 13:06
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hey mocha its insulation foam so you can get it from any DIY store, but mike will be able to give you more detail

by ryaoki on Sunday, 1 June, 2008 - 13:21
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huzzah for celotex :) bet they didnt anticipate giant weapons being made out of it 8D ..

by Ikkaku-kun on Sunday, 1 June, 2008 - 14:36
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this will be awsome to see, always wanted someone to cosplay this guy.

by nanahara on Sunday, 1 June, 2008 - 20:21
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Thanks for your support guys this is one im really looking forward to as well XD

Im using everything ive learned over the past year plus trying out some new things too so wish me luck XD

by MangaChild on Monday, 2 June, 2008 - 10:36
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you dont need luck...
i swear you have jars of awesome that you paint everything you do in!!

really looking forward to seeing this progress, mega muscles here you come!!

by HelloKitty on Monday, 2 June, 2008 - 14:53
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Sanding??? by hand??? Bahh :P do what i did and use a power sander and no face mask xD ...... its lookcing wicked :)

by Ikkaku-kun on Monday, 2 June, 2008 - 21:27
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I've never really understood how to fibreglass, do you heat up the sheets and then press it down to the shape you want?

by Odd-One-Out on Wednesday, 4 June, 2008 - 17:00
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Theres 3 parts to fiberglass...

Theres the cloth its self
The Hardener & The Resin which you mix...

I Paint the base in the Hardener & resin mix then lay the cloth on top then paint over the mix over the fiberglass cloth...

It does bugger uyp the paint brushes and you cant get any on your self so make suyre your well covered...

I am writing a guide in time so ill forward it on once i have..

by MangaChild on Wednesday, 4 June, 2008 - 17:09
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wooot for stinky fiberglass.... just dont get it on ure hand then itch ure hair ;) thats where i went wrong 8D

by Ikkaku-kun on Wednesday, 4 June, 2008 - 18:56
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MY GOD! the sword looking amazing! >8D something else on my steal list then lol

i cant wait to see this finished! soooo need a pic of you!!!

good work!!!!!!!!!

by Kaka Extreme on Monday, 9 June, 2008 - 00:31
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mike its fucking amazing, and its not a ugly mug( make me one for my room handsome lmao) you must teach me hot to do this lol

by ryaoki on Thursday, 19 June, 2008 - 21:52
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When you pull this off you will officially win at everything. :D

Looking completely and utterly AMAZING so far!

by BlusterSquall on Thursday, 19 June, 2008 - 21:56
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You have joined the have-small-statue-of-own-head clan \o/

Looking good so far!

by nert on Saturday, 21 June, 2008 - 19:38
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Meeps the weapon making sounds complicated but looks ubar so far! I will have to poke Amber to get your secrets. :P

by ChibiVampireM on Saturday, 21 June, 2008 - 23:41
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Ah the jaw's no problem, just meant a LOT of plasticine, once there were enough layers of latex on it just holds its shape and it meant I could cut a huge breathing hole where his palette should be XD

The real pain is being able to see..

by nert on Sunday, 22 June, 2008 - 09:47
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ahh amazing....i wish I COULD be a Yurimaru for you -_-

by 1000014 on Friday, 4 July, 2008 - 00:52
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Brilliant mask.

Are you still working on the sword? Ain't seen any pics for a while, is all.

Be sure to post photos of the finished cos on here, can't wait to see it!

by behind_you on Wednesday, 9 July, 2008 - 13:10
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thanks for the comment on kanetsugu man, i WOULD HAVE NEVER have got this far in cosplay or pushed myself this far if it wernt for the help of you and amber

and i cant wait to see this as its going to be immense, can u get me in a head lock and take a pic with this on lmao

by ryaoki on Thursday, 17 July, 2008 - 17:03
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MISSION...COMPLETE good job mike

by ryaoki on Saturday, 2 August, 2008 - 15:08
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Jaysus man, it's complete and you've NOT put a SINGLE pic up? You're cruel, bud. Cruel XP

by behind_you on Monday, 4 August, 2008 - 12:15
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cant wait to see this at ame gotta love nija scroll looking epic mate

by Defrain on Tuesday, 5 August, 2008 - 18:10
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glad to see some non-blurry pics. this cos keeps on impressing.

good to meet you guys!

by behind_you on Wednesday, 13 August, 2008 - 20:00
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haha i loved this cosplay and seems that while wearing it it gives you 3 times the strength(experienced first hand with slipper and chest punch lol) GOOO ROCKY FOSTER cant wait to see you next man and good luck

by ryaoki on Wednesday, 13 August, 2008 - 20:03
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this was one hell of an amazing costume! so glad i got to see and got a chance to wield the god almighty weapon tooooooooo!!!! good job!!!!!! *bows*

by Kaka Extreme on Wednesday, 13 August, 2008 - 20:03
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This costume was beyond epic mate, well done!

by Leadmill on Wednesday, 13 August, 2008 - 22:58
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The photo with you in the darkness is great :D

by Odd-One-Out on Thursday, 14 August, 2008 - 18:21
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Truly an epic body suit, I thought you captured the whole look very well.

by Ilpala on Thursday, 14 August, 2008 - 18:41

That was one awesome cosplay :)...and thats our arm your eating :O

by airyfairy on Thursday, 14 August, 2008 - 21:49
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thanks for the hand XD

no pun intended :P

by MangaChild on Thursday, 14 August, 2008 - 23:06
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thank you very much for you nice comments on Terry. i Loved this one when i sawi it,as you know. im gonna be tryin g more masquerades,so ill see you in them,no doubt :D

by terandir on Tuesday, 19 August, 2008 - 11:53
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Ooh! That was you??! Brilliant cosplay! =D

by Mtani on Wednesday, 20 August, 2008 - 01:20
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Incredible and totally scary! Didn't realise it was you XD You must be so proud of this, so much time and effort, way to go!

by Amy-Lou on Wednesday, 20 August, 2008 - 19:27
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I got the first comment, but I'm adding another because seeing this in person was just TOO DAMNED COOL!

This rocked Mike, well done! I know you suffered quite a bit when making the weapon too dude, but it looked amazing!

by sjbonnar on Wednesday, 20 August, 2008 - 21:59
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This must have been petrifying in person, I bet you managed to confuse everyone who didn't know it was you inside. Thank you for writing up your construction notes, it was really interesting to read how you made this awesome costume :O

by Tak on Wednesday, 20 August, 2008 - 23:54

I think you set the standard on LIFE :D absolutely amazing!!!!

by on Friday, 22 August, 2008 - 19:44
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Just read your notes ~ it only took you FOUR DAYS?!! I'm suitably impressed! Haha, can't believe it was 4 hours before I actually realised it was you LOL

by Orihime on Saturday, 23 August, 2008 - 06:05
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the whole cos took two and a half months to make, sorry its the way i wrote the notes.

We spent 4 Evenings trying to get the trousers to look right, although i bought the right pattern i forgot to check the size which was a ladies 12 hence the not so bagginess.

by MangaChild on Saturday, 23 August, 2008 - 10:52
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Absolutely incredible! Please rewear this to expo!!!

by stripey_dani on Wednesday, 27 August, 2008 - 14:12

I love this, im aiming to do full body if not semi body latex work myself at somepoint.


by Moozman on Thursday, 23 October, 2008 - 15:59
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Excelent costume there, I was one of the first to have noticed yer costume as I love Ninja scroll aswell^___^

very epic costume, I hope to see yer in Neomag^__^

by Anime_Angel on Wednesday, 29 October, 2008 - 22:23
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ROFLMAO hahaha ahh i no i am a awsome photographer yeaa all i keep doing is button bashin the camera until it takes a funny photos LMAAO im so not professional lmao AND ITS POP U BRIZZLE IDIOT POPP NOT JUICE, WHAT ARE YOY AMERICAN

by ryaoki on Friday, 7 November, 2008 - 20:01
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LMAO love the new pic hahahahahhahahahahahahahahahah goes so well with the cos LOL

by Kaka Extreme on Friday, 7 November, 2008 - 20:22
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lol gotta love reiss and his out ragous photos

by Defrain on Monday, 24 November, 2008 - 12:42
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Ninja Scroll is the film that got me into anime! It's so amazing to see Tessai done so perfectly! I can't imagine how hard it must have been to make... YOU ARE A COSPLAY GOD!

by PKNIVES on Thursday, 2 April, 2009 - 16:55
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You've never looked prettier mike ;) lmfao!

by Ikkaku-kun on Tuesday, 28 April, 2009 - 23:50
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That's was an amazing Tessai cosplay and Ninja Scroll is one of the best anime flims i've ever seen and I love it. XD

by RebaSephiroth2 on Wednesday, 9 February, 2011 - 17:11


Torso 7 (Posted 3rd July 2011)

Back again

Torso 6 (Posted 3rd July 2011)

Painting the back... being careful not to glue the Zip shut

Torso 5 (Posted 3rd July 2011)

Painting Continued.
Forgot to mention the arms are painted separately so they don't end up glued to the torso

Torso 4 (Posted 3rd July 2011)

The Paint!!
My Mortal Enemy!!
I hate painting!!!
The paint is Acrylic Paint mixed with Liquid Latex mixed in a large volume as paint matching and acrylic latex mix isn't something easily done.
The paint was applied using a house hold paint brush to avoid brush strokes you can use a sponge to dab paint on, if the mix is too runny add Latex thickener to increase the consistency of the mix.

Torso 3 (Posted 3rd July 2011)

Left and right sides of the back done

Torso 2 (Posted 3rd July 2011)

Further progress on the back

Torso 1 (Posted 3rd July 2011)

Slabs of foam are glued on the torso using evostick or latex.
They are then carved in to shape and layered up if needed.
This pic shows the arms as complete and the back is just starting.

MONTAAAAGGGGEEEEEE (Posted 3rd July 2011)


MOAR!!! (Posted 3rd July 2011)

Just found some old images of progress pic's which will hopefully give a better idea of how I construct body suits :D

I guess I didn't have the time to previously upload them then forgot... so sorry but here they are

The Mask - Part 2 (Posted 12th September 2008)

Once the Plaster head cast was set as per Nerts guide i built up plastercine on top to add the facial features of Tessai.

When i was happy with look of the Plastercine model i painted on top about 10-15 layers of latex, also i added a further 2 or 3 top coat layers of latex mixed with acrylic paint.

Once this has all set peel away the latex mask and the job is done.

The Mask - Part 1 (Posted 12th September 2008)

To make the mask ive had to make a cast of my head thanks to Nerts great guide found on the articles section of Cosplay Island, and Ambers Wonderful help and patience while i panic'd with my head Sealed in Alginite :D

I was also helped by a few pointers i found:
About 5kg of paster is needed to fill the avreage head cast
The average head cast needs roughly 500-600g of alginite
The slow set alginaite sets very fast
Do not use Hot water with alginaite as it will set instantly
Breathing through a tube isnt fun at all :(

Its worth all the work tho when you have the Result :)

The Sword - In Progress 7 (Posted 8th September 2008)

Always try to spray in a clean dust free envirement for a great finish, ALWAYS wear a mask and work in a well ventilated area.

Normally i use Plasticote Primer, Topcoat and Clear Sealant spray paint for a long lasting finish, Use the cans as directed and you cant go wrong :)

The Sword - In Progress 6 (Posted 8th September 2008)

Now the most difficult part Bondo..

Bondo is just regular car bodywork filler its a mix this time of paste and hardener, once the Paste and hardener are mixed its pinkish in colour...
Bondo is used to fill the dips and dents on the sword to give it a smoother more level finish.

Once Mixed you spread the paste over the desired area and Skimm off any excess, then allow the mix to harden &amp; sand down the rest for a good finish..

You repeat this over and over untill your satiffied with the finish or ran out of money for more bondo.
To bondo the whole the sword took me 3 evenings to complete (about 6-8 hours of power sanding).

Now its ready for primer and Painting :)

The Sword - In Progress 5 (Posted 8th September 2008)

The Beginning of fiberglassing
Okay here comes the science part... lol not really
Basically you roughly trim the glass cloth using a normal pair of scisors to fit the surface area you wish to cover..

Then mix thoroughly the Resin and hardener, 8 seconds worth of Hardener per 50ml of resin, very roughly and this varies with outdoor temperatures....

Then paint the surface area in the Resin/Hardener Mix and lay the Glass cloth on top.
Then paint the same mix on top the glass cloth trying to ensure you create as few bubbles lumps and bumps as possiable...

The Sword - In Progress 4 (Posted 8th September 2008)

Now for some sanding down by hand... well about 4-5 hours worth as powertools are too boysterous for Celotex (InsulationFoam) :s

The Sword - In Progress 3 (Posted 8th September 2008)

After marking up my base i cut out the shape using a fully extended Stanley knife blade, now its ready for shaping.

The Sword - In Progress 2 (Posted 8th September 2008)

After making my template i placed it on my base (Rigid Insulation Foam) and drew round my chosen side, i then flipped over the template and drew on the same side side to have both sides match.

The Sword - In Progress 1 (Posted 8th September 2008)

First of all i study the reference from every available angle and Think about the best approach for getting the right shape. I then Drew out this template and cut it out, realizing it wasn't symmetrical i choose one side to use then flip it over.