Costume :Aerrow
Source :Storm Hawks
Progress :In Progress
Worn At :MCM London Comic Con May 2015

Costume Photos

Aerrow Mock up Progress

Radarr Progress #1

Radarr Reference Art


Poster Art

Official Reference Sheet


Costume Information

I have been a Storm Hawks fan for a number of years, and I feel that I now have the skills to pull off one of my favourite characters from the show - Aerrow. He's the Sky Knight of the newly reformed Storm Hawks squadron, and the last descendant of the original team's leader. Despite being too young for a pilot's license, he's one of the best flyers around and a skilled fighter.

His costume is made up of many different elements, including sewing, armour, wig and electronic prop work. I aim to create a realistic look to this costume, while still staying true to the more stylised areas too. It's likely to prove a challenge to make some of these things believable. Apart from that, this is a relatively simple design, and should work in my favour since I will be able to concentrate my efforts in smaller areas, and (hopefully) create a more polished outcome.

This one I can't wait to work on, and I may just have to rewatch the entire series as I do. The sky's never the limit!


Avatar Image

Omg!!!! I had completely forgotten about this show!!! What a blast from the past! ;___; I used to watch it religiously as well D8
Can't wait to see the progress of this!!!

by Koiice on Saturday, 11 January, 2014 - 00:55

love the show. looking forward to see the progress

by gxgirl-93 on Saturday, 11 January, 2014 - 14:53

To-Do List

BootsHighIn Progress
Defaced Banner (for performance)HighPlanned
Backdrop (for performance)HighPlanned
Shield (for performance)HighPlanned
Sword HolstersHighPlanned
Joint PadsHighPlanned
Mock up - TrousersMediumIn Progress
Mock up - Joint PadsMediumIn Progress
RadarrMediumIn Progress
Mock up - JumperMediumIn Progress
Swords (Flared) (for performance)MediumPlanned
Mock up - GlovesMediumPlanned
Mock up - SwordsLowPlanned

Shopping List



Radarr: Head - Scale! (Posted 26th February 2015)

Selfie to show the scale of Radarr's face! ;D

Radarr: Head - Ears pinned (Posted 26th February 2015)

He has ears! Well, pinned and taped... I can't fix them until I fur him, I need to open them up to add wire supports and such... They may look a little big at the moment, but his neck will soon fix that...

Radarr: Head - Poseable eyebrows (posed) (Posted 26th February 2015)

Here are the eyebrows posed, they are quite flexible, it'll take some practice to achieve the expressions I want him to wear quickly.

Radarr: Head - Poseable eyebrows (Posted 26th February 2015)

Some little sky monkey has a pair of poseable eyebrows! :DDD This was quite an experiment, and it took me two attempts to get this. All it is is craft foam and wire, and I'll be using the same technique with his mouth after furring (his lip needs to be exposed, whereas his eyebrows aren't defined in the same way)

(here they are in a neutral state, this is how I will be working with them until I finish the project)

Radarr: Head - Sculpt complete (Posted 26th February 2015)

Radarr's head is pretty much fully sculpted! He needs a fuller brow yet, a little patching in areas, and I'm going to be changing his eyes soon, but he's coming together pretty well! I'm not too worried about getting him completely smooth, he's going to be covered in fabric anyway so it's be a waste of time going too far.

I have to admit seeing him slowly come to life is really exciting <3

Radarr: Head - Slooowwwlyy (Posted 26th February 2015)

I'm sloooowllyyy chipping away at it

Radarr: Head - The derp stage (Posted 26th February 2015)


Radarr: Head - The start of the sculpt (Posted 26th February 2015)

I've trimmed away all the differences in the templates and started having a go at rounding areas off. It's very much a brick still, but as I chip off more and build up confidence to move away from the templates, it'll start to look more like the sky monkey I'm aiming for <3

Radarr: Head - Templates Marked (Posted 26th February 2015)

Got the templates done, now to start hacking off foam (aka the hella messy bit)

Radarr: Head - Templates Down (Posted 26th February 2015)

I scanned, printed and cut my drawn reference to create a set of templates to mark up my foam.

Wooooo it's been a long time since I've done a head sculpt... Let's see how rusty I am haha

Radarr: Head - Dummy run eyes (Posted 21st February 2015)

My trial eyes for Radarr, cast out of hot glue. I've never cast with hot glue before, but it's the /perfect/ shade of off-white for the job. This set is covered in ridges, so I'm using them just to help me with my foam build until I get the real ones done (also why this is such a crappy paint job haha).

I'm not sure when I'll start on the foam build yet, but I want to see if I can get more of Aerrow done first (I need to heat form some craft foam to cut the shoulder pad patterns).

Radarr: Head - Drawing (Posted 21st February 2015)

Using this as reference for my sculpt, it's actually a little over a year old now, I originally drew it back when I first started planning on making Aerrow, until Smaug took priority.

You'll probably notice that I've made his eyes a little smaller than in the show. I think in real life it'd look a little too bug eyed, but they are still pretty big on the head. I've rounded a lot of things off style wise to make them translate to real life a little better.

Incoming Radarr! (Posted 21st February 2015)

It turns out I need a bag for when I have my Aerrow costume at cons (pockets can only do so much), and since I've found a way to incorporate him into my May MCM performance plans, I've decided I'm going to make Radarr. Besides, what kind of Aerrow would I be without a Radarr hanging off my back!? He's going to be quite an experiment that's for sure, but there's a lot of techniques involved that I have got experience with (by the looks of it, his clothes and bag are going to be the hardest). Fortunately I can make him mostly out of things I already own, or will do as I progress with the costume (which takes priority after all).

There are tests to be done!

Shoulder pad patterns (Posted 19th February 2015)

Shoulder croissant-- I mean, shoulder pad patterns are done! I duct taped each segment individually so I can get the hidden areas in too. Foam tests next.

Shoulder pad shapes (Posted 18th February 2015)

This delectable loaf of duct tape is my shoulder cast, now sporting the shapes I need to make the pattern for my leather pads.

Dark blue is the outline, red is the middle segment, the yellow marks the overlapped areas of the top and bottom segments. The mark in the corner of the middle segment marks the pivot point, there's one on the other side of the arm too. The bottom segment is fused to the middle piece, connecting it to the sleeve. Originally I was going to have the top be fused to the shoulder, but depending on how restricting this is for my movement, I might only fuse it to the sleeve seam.

I need to duct tape out each piece individually next, then I can trial it in craft foam. I'm surprised I've made it this far haha!

Damn shape! (Posted 18th February 2015)

My dilemma at the moment with my shoulder padding pattern. I have to be careful how I alter it or it'll just fall flat against my shoulder and lose the shape I had padded out.

Messing with reference art (Posted 17th February 2015)

What started out as a joke to see how much I need to change Aerrow to make his outfit fit me went a little further than I thought, and became a potential reference. In some way this is a lot more tangible to make now, but it's really weird for me to see these two next to each other haha. (yay for about 45 minutes in photoshop with nothing but a mouse :P)

Shoulder pad template (Posted 15th February 2015)

Huzzah, a pattern! (Modelled by my mock up of Haruhi's dress haha)

I've still got some altering to do to get it to match the shape of the reference, but it's coming close. This stage is to get the perfect resting shape, then I can use the pattern to draft the individual segments to increase my range of movement. Hopefully I won't have to go into such heavy drafting for the elbows and knees, they cover smaller areas...

Cheap duct tape is a fantastic thing.

Shoulder pad mock up progress (Posted 14th February 2015)

This was so hard to do without help, but with patience, a lot of cling film and three small reels of duct tape, I finally have a base for my shoulder pads done. I do admit, I've been worried about the width of my shoulders for this costume, but if the pads look anything like this I should be perfectly fine. It even came out to a point like in the design! Haha

I'm going to make a pattern and trail it with foam on the mock up. I might need to do some tweaks to my plans for the movement, since I'm a little anxious about how it'll distort the jumper... I'll have to work on that.

Needless to say I'm pretty happy with this!

Boots! #3 (Posted 12th February 2015)

(a better view of the nail polish remover stains)

Boots! #2 (Posted 12th February 2015)

(a better view of the nail polish remover stains)

Boots! #1 (Posted 12th February 2015)

My boots arrived! The colours are spot on, and they fit amazingly (minimal breaking in, yay!). The seller put them up for auction because she'd spilt nail polish remover on them, but the don't look half as bad as I thought they'd be, I can play around with different weathering too if I want them to blend it in a little better. I also might make them shorter to match the proportions in the reference art, depending how hard it'll be to sew haha.

Shirt mock up progress (Posted 8th February 2015)

Whew! I got the red sections sewn in last night, I just need to tidy up the seam allowances so they lay flat. Like I said before, the method I used for the mock up meant I wouldn't get a perfectly symmetrical piece, however I do have a pattern now and will be able to make it even for the final attempt. Everything still needs hemming and the waistband of the trousers still needs to be sewn on. After that's sorted I can worry about the leather shoulder/elbow/knee pads.

Death by bright colours (Posted 8th February 2015)

Hissss this is trickyyy...and these bright contrasting fleeces are killing my eyes! ;-;

Smaller Collar (Posted 8th February 2015)

New collar trial! I'm much happier with the fit now, it's much snugger and much harder to pull over my head, but it leaves far more room for the shoulder pads and the holsters :DDD yay for stupid o clock progress!

The Red Patch (Posted 8th February 2015)

Robin redbreast jokes incoming...

The red jumper patches are ready to have the collar sewn in. The neckline's about a centimetre snugger, but I can still get my head through (albeit with some force while the seam allowance is unclipped). I'm a little annoyed I could get the mock up completely symmetrical, but it means I can get the final thing to sit perfectly.

Testing the sleeves (Posted 7th February 2015)

I'm fitting the sleeves tonight~ Pretty happy so far, I just need to sew in the left one now. I'm a little sceptical about the collar fitting, I've planned to take it in a little to fit a little more snug. Only a tad though. I still need to decide on how I'm going to hem it...

Sorry about the crappy binding effort here haha, it'll be a lot smoother for the real trial runs. I can work in my binder but not the vests as well (I like breathing).

Pattern Alterations (Posted 29th January 2015)

Getting these bloody alterations done at last. It's probably going to need more than this, but we'll see how it looks.

Mock up leggings (Posted 24th January 2015)

I managed to transfer the alterations but I don't trust the pattern at the moment, so I'm going to do another attempt on cheap fabric to make sure it's going to work. It should do, but I'd really rather not risk it. I also need to put on the waistband, but I might not bother until the redraft to save my elastic.

Also, the second two pictures are why we have with-nap layouts ;) I only did it cut yardage costs for the mock ups, the final thing will be done correctly.

Leggings Alterations (Posted 23rd January 2015)

I'm currently working on his trousers, though with how tight they have to be, they're closer to being leggings haha. I still have a long way to go to get these to fit perfectly, I won't know 100% until I put in the waistband, and that can't happen until I finish the legs :')

Patterns Patterns Patterns~ (Posted 22nd January 2015)

I'm drafting my own patterns for Aerrow.

Shoulder pad planning (Posted 21st January 2015)

I've spend my day doing armour research, trying to find a way to get as much movement as I can Aerrow's the shoulder padding. I think I've finally found something that's going to work.

Looking at the way spaulders work - several overlapped bands (called lames) joined by straps of leather or rivets - it gave me an idea of how to engineer this. I was able to find a purpose for the little rivets in either side of his shoulders too. The way I have drafted it out so far is that there are three lames, the two lower ones overlapped normally and fused together (this doesn't need the movement, and will make attaching the piece to the jumper easier). The top piece covers the shoulder underneath the larger middle lame. There's a curve in the middle lame that will pass over the shape of the piece it covers, which will open up a huge amount of movement if it works.

This part has been incredibly hard to sort out, I don't want to sacrifice too much accuracy, but the design as it is wouldn't be able to work in real life without distorting. The plan I've drawn out could work, or not at all. I'm going to have to do a mock up out of foam first before going onto leather. All I really need to worry about now is how much movement the knees and elbows will have, and if there's anything I can do to make them have a little more range without any visible attachments.

Whew this is a tricky part ;____;

Wig Research (Posted 20th January 2015)

Oh boy has today been busy. With Coscraft opening up again, I've been making more definite plans for Aerrow's hair by comparing potential styles and colours I want to use.

Aerrow has a lot of spiking work to be done, a huge amount of ventilating/franken-wigging, and no visible parting in the back (how I'm going to get around that is going to be the most fun...). The wig is possibly the biggest thing that I want to get as accurate as possible, since it's one of the most defining part of his silhouette. I have a fair bit of experience with styling wigs, and a lot of the techniques I want to use, but I've never used them at this scale in the same project. It's going to be a lot of work, but I want to be certain that the materials I want to use will be right first, so it's going to take some time.

I'm almost tempted to call this build Project Hedgehog at this rate hehe

MyFabrics Samples (Posted 17th January 2015)

Ahaha my new samples arrived! I think I have most of the fabrics I need now (a mixture of cuff knits, fleeces and sweatshirt fabrics). It's very hard to photograph without proper daylight, but the colours match as much as I hoped (<3!!), and I should be able to order what I need once I have the mock up done (I need to get the correct amounts).

Aerrow Colour Palette (Posted 17th January 2015)

I've made up a colour palette for Aerrow to make my fabric matching a lot easier.

Sword Template #2 (Posted 14th January 2015)

Second attempt at the sword template. This time I stayed true to the reference art, and only shortened the length of the hilt. Hopefully between the two drawings, you should be able to see just how different they are in shape, and I certainly prefer the new one. The blade looks a lot bigger with the guard being smaller, and I prefer the deeper 'cut out' sections. The overall size I'm going for with this is just under a full arm's length from tip to pommel, so these are going to be pretty big daggers.

Next I'm going to draw up the rough interior arrangement, though I won't be able to make anything final until I know the dimensions of the EL wire drivers. It's still going to make things a little easier to understand if it's drawn up, and I'm probably just going to have to change a little bit of the scaling that's all.

Make up test: attempt 1 (Posted 14th January 2015)

I hate doing make up tests without the wig to match, but I've made so little progress today I couldn't resist seeing what I could do. I'm definitely going to have another attempt another day, but it more than likely won't be until the wig is done. I generally know what I want now so it should quicker next time (ie the eyebrows, eyes, contouring).

Ugh make up I hate you so much ;-;

Sword Template (Posted 12th January 2015)

Here's my first attempt at my Aerrow sword template! Woah SAI is so much easier to outline with than illustrator. I might have to go over my Buccaneer arm again in there.

Quick history lesson: Storm Hawks was going to have an MMO called Storm Hawks Skyrace, and they hyped it up quite a bit. After the show was cancelled, the game quickly followed suit. However, a lot of the models and artwork were released by the artists for their portfolios. One of the things released was a full view turn around video clip of one of Aerrow's swords, and his is going to be incredibly useful for my own build.

I've had to alter the proportions for my version. In the show and artwork, the swords lights up and make a more impressive look. But because I'm having to use EL wire to create a live edge, I'm going to have to make the blade a little larger, and the handle smaller. The official merch does this as well, but I've not altered it that much, this is more of a balance between the two. This is still only the first attempt, I might still have to alter them a little more, but I'm pretty happy with the way it looks for now.

Calico Fabric Samples (Posted 3rd January 2015)

My fabric samples from Calico Laine arrived today! The top two are samples for Haruhi (the best colour matches I could find in 100% cotton), and the other eight are for Aerrow.

The fleeces have incredible amount of stretch (far more than the fabric I used on Smaug), which is going to be perfect for Aerrow's range of movement. So far I think the dark petrol fleece is the closest colour match with the jumper (second to the left bottom left) the rest are a little too purple.

I'm definitely going to be hunting for sweatshirt fabrics too, especially for the red portion on his front. The padded look will be really effective against the fleece, and maybe make it look a little less like a set of pyjamas haha. If I can't find the pale red I want, I'll have to experiment with acid dying. If that doesn't work, I'll have to find another way around it.

Project Aerrow! (Posted 29th December 2014)

After years of putting off, I've finally gotten the guts to start this thing.

I still have a lot to sit down and plan out thoroughly, but things are slowly becoming more and more tangible. I'm very glad I've waited to start this project, I've picked up skills and experience that I will definitely need for it to run smoothly. Each part of the costume is going to need a substantial amount of attention to bring it up to a standard I want to compete in, some more than others. And by others I of course mean those swords. I've devoted the entire day planning how those things are going to be dealt with, and they are going to need plenty more in the weeks to come.

The goal is to get him finished in time for May MCM. Whether or not I can pull it off is another thing entirely.