Sith Warrior - Star Wars The Old Republic

Worn AtLondon MCM Expo October 2011
Showcased 5th February 2012 What is this?




A Sith warrior from the upcoming Old Republic game by Bioware. To be paired with PhantomShadow and his Jedi on the Sunday of Expo for the Masquerade in the elites catagory and Eternal_Aranel with her Jedi on the Saturday.

This game is yet to be realised and as such only screenshots and art have been realised. While I am using designs and such the armour is largely of my design and tbh Im making it up as I go along XD seems fitting for an mmo game based cosplay tbh. Hopefully the end result will be good.


Telly posted on 4 September, 2011 - 22:36
Lovely work on the robe, it hangs beautifully!

Sunsetdancer posted on 5 September, 2011 - 07:15
Thank you I still have to shorten it slightly so it doesn't drag so much.

Manticore posted on 10 September, 2011 - 20:01
Looking Cool right now dude! Wondering if you'll pull it out For October Next Year... got something Special planned and DEFINITELY requires Sith..

Sunsetdancer posted on 12 September, 2011 - 20:33
Unfortunately this will be my last expo for a while. The group has decided to give them up and concentrate on cons from now on. But you never know.

Manticore posted on 15 September, 2011 - 18:43
Thats fine I guess I'll still be around for Con's depending on where though

Sunsetdancer posted on 15 September, 2011 - 18:54
Mainly Kitacon Ayacon/Amecon

lastordersuk posted on 17 September, 2011 - 15:01
looking good!, wondering what you used to make the pattern and detailing on your chest armour?

Sunsetdancer posted on 17 September, 2011 - 16:22
The detailing in engraved free hand into the armour using a dremel.

GAINAX posted on 18 September, 2011 - 01:03
Looking forward to this! MAY THE FORCE BE WITH YOU. ... Sorry.

Mikado posted on 19 September, 2011 - 11:35
looking good man, i will have to track you down for a photo

Sunsetdancer posted on 19 September, 2011 - 21:01
Ill be about Sat and Sun of Expo all plans staying the same. :D

Elle posted on 23 September, 2011 - 08:55
the chest armor seems very difficult to make. What is the material of the armor? Is there foam in it? How could you make it so muscle-like?

Sunsetdancer posted on 27 September, 2011 - 21:37
Hey Elle, The armour is made out of EVA foam, which you can buy from places as thin sheets BUT I have opted for using interlocking floor tiles used in gyms and such. It requires a lot of messing around tbh. First you have to template what you want, remembering that once the foam is heated it will shrink slightly and bending it reduces the length. The a heat gun is required to heat the foam to shape it, being very careful not to burn yourself (the heat gun is set to 600c), then hot glue the parts together. Adding clips and such to make it wearable. Adding layers for detail. Adding detail using a dremel and such. Basically patience and a little know how with some added common sence. You can follow all my progress pics at;!/media/set/?set=a.2077755152499.2098288.1503609146

Ranma1-2 posted on 27 September, 2011 - 23:32
Nice work, the robe looks really neat, I love the lines..reminds me of Mauls outfit. Hope I spot you around Expo. Which day will this be?

Sunsetdancer posted on 27 September, 2011 - 23:39
Thanks the robe was a pure fluke it came out that good tbh. The expensive material helps though. Will be for both days.

Ranma1-2 posted on 28 September, 2011 - 15:04 the fabric raw silk??

Sunsetdancer posted on 29 September, 2011 - 17:55
I have heavy wool flannel for the cloak which is as close as the real thing used as I could get.

Ranma1-2 posted on 29 September, 2011 - 23:23
Yeah it does look good. :)

SnowmanKline posted on 7 October, 2011 - 10:40
DUDE this looks so awesome so far :) was thinking of doing Darth Malges from this game some time next year.

Sunsetdancer posted on 9 October, 2011 - 17:14
Darth Malgus!!!!! YES!!!! You NEED to do it!

No thanks posted on 11 October, 2011 - 16:29

nanahara posted on 16 October, 2011 - 00:12
duuuuuuuuuuuude XD

eternal_aranel posted on 16 October, 2011 - 00:13

Frederica la Noir posted on 18 October, 2011 - 13:34
Wow, the progress on this looks amazing! :D

Sunsetdancer posted on 19 October, 2011 - 21:53
Thanks guys hopefully to be mostly finished by Sunday

Manjou posted on 23 October, 2011 - 19:46
Been following your progress for a while, it's looking excellent :) I was just wondering what kind of paint/methods you used on the foam to get that effect?

Sunsetdancer posted on 23 October, 2011 - 20:36
Ive been painting warhammer for like 15 years or something so I just used exactly the same methods on this. I make up a basic darkish grey for a base coat. I used an airbrush to apply this for quickness and smooth evenness. Then mixed up a lighter grey and used the dry brushing method all over. This will give the weathered effect. Then uing a flat large brush I used a modified dry brishing method using more paint than the normal dry brush method to work on the silver for the worn away look. Took a lot of time and effort but I think the overall look has come out really well. The paints are simple acrylics.

Leolarua posted on 23 October, 2011 - 22:13
this is looking great so far! i really like your paintwork

Ragepotato posted on 26 October, 2011 - 03:01
Looking amazing ^_^ Hope to see it in person over the weekend! 8D Gonna be looking out for that sick paint job. -Phi

Numta posted on 27 October, 2011 - 14:20
epic work! looks amazing!

Angelphie posted on 1 November, 2011 - 21:28
So impressive and nicely made. The armour, its detailing and painting is very neat and I like the LEDs. Also love the smartphone holder on your arm, great idea!

Sunsetdancer posted on 3 November, 2011 - 12:18
Thanks guys. Actual expo photos coming soon.

eternal_aranel posted on 4 November, 2011 - 12:10
Was amazing doing this with you. You looked awesome! Thanks again man x <3

Toshi-chan posted on 14 November, 2011 - 09:02
So much awesome ^.^

Littlegeeky posted on 5 February, 2012 - 18:03
Wow this is such an amazing cosplay! The amount of detail is just brilliant! Congratulations on the showcase!

Fishyfins posted on 5 February, 2012 - 20:44
gratz on the showcase dude! fantastic cosplay ^^

Sephirayne posted on 5 February, 2012 - 21:00
This is epic. Love the armour. Congrats on the showcase

Kinreal posted on 6 February, 2012 - 03:02
Congrats on the showcase dude! Deserves it! :D

No thanks posted on 7 February, 2012 - 01:58

SnowmanKline posted on 7 February, 2012 - 10:21
Congrats on the showcase mate. this looks awesome!

Emzone posted on 7 February, 2012 - 17:35
Totally deserved!

eternal_aranel posted on 7 February, 2012 - 18:01
YES. ABOUT TIME. Also I was right :P

Sunsetdancer posted on 7 February, 2012 - 19:04
Thank you Emi your photos were awesome! Laura seems your so right when it comes to things like this.... And square things....

Leolarua posted on 7 February, 2012 - 21:26
gratz on the showcase! well deserved

Sakurastar123 posted on 7 February, 2012 - 23:50
This absolutely deserved a showcase! Your costume was absolutely amazing, I was so impressed with the paint job when I saw it. Congrats ^-^

Sunsetdancer posted on 8 February, 2012 - 19:11
Thankyou everyone, I worked really hard and glad to know people like it

kitty_sama posted on 16 February, 2012 - 13:58
I can't believe I haven't commented on this before! This is bloody amazing and deserving of a showcase. Congrats!

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Progress Journal

Nearly Finished :D (Posted 23rd October 2011)

Completed the boots and the lower leg armour. Started to modpodge them and paint them. Also mounted the pockets onto the belt armour.

More Painting (Posted 22nd October 2011)

Painted the chest and back plates. Also Josh found some split pins to finish off the effect.

Painted 1st Thigh Section (Posted 19th October 2011)

Painted 1st Thigh Section

Painted Gauntlet, Belt and Glove (Posted 18th October 2011)

Painted Gauntlet, Belt and Glove

Painting and Boots (Posted 16th October 2011)

Started the paint the belt

Started construction on the boots

LEDs, Gloves and Arm Armour (Posted 15th October 2011)

Josh wired up my LEDs today for the belt and the front and back of the chest.

I started and finished a gauntlet.

Also, started a arm armour section and added the ipod to it.

Gloves, Pouches, LEDs & Makeup Test (Posted 13th October 2011)

Started the gloves by adding the nails.
Charlotte made two pouches for the belt and clip harness.
Mounted the LEDs into the armour.
Second makeup test done by Charlotte.

Boot Work (Posted 6th October 2011)

Started moulding the upper boot base and added the clips. Run out of hot glue sticks so no more work until these arrive. :/

Template boots (Posted 5th October 2011)

Templated and cut out the foam for the armour boots.

Thigh armour time (Posted 2nd October 2011)

Templeted the thigh armour, cut out the pieces, shaped them and added detail to one of them. Covered in PVA to seal.

Also ironed the coat flat.

Added Shoulder Pads (Posted 30th September 2011)

Added the shoulder pads to the armour.

Adjusted the coat sides (Posted 29th September 2011)

Sorted the coat sides and hemmed them

More Coat (Posted 27th September 2011)

Hemmed the edges, the bottom and added the sleeves and hemmed them.

Josh was also kind enough to mess up his gauntlets so I can have them since they fit me fine, cheers.

Coat Beginings (Posted 18th September 2011)

Pattern cut out. Pieces cut out and the main coat shape sewn followed by the collar.

Belt Beginings (Posted 16th September 2011)

Belt armour templated. Then cut and shaped and stuck. Then I done more detail work on the chest piece.

Layering the armour (Posted 15th September 2011)

Layered the front chest piece

Cut out coat pattern (Posted 14th September 2011)

Coat pattern cut out.

Armour Straps (Posted 12th September 2011)

Added straps to the armour so it fits me and moulded it some more. Im now happy with the basic shape.

Armour Begins (Posted 11th September 2011)

Templated the base armour. Cut out the foam sections and started moulding.

Cloak Finished (Posted 7th September 2011)

Completed the cloak today by sizing and hemming the sleeves. Also the bottom of the robe to my size. Also added the collor section to hide the seam around the neck.

Cloak Beginings (Posted 4th September 2011)

Started the cloak by cutting out the material, and then piecing it together using the overlocker. Then made a hood pattern from a guide on the internest and pleated it to fit my cloak.

Need to hem the sleeves, hem the bottom and add the collor.

Bought Material and Patterns (Posted 28th July 2011)

Bought the material for the cloaks and the coat today along with the patterns needed. £177 all in all...