Priss Asagiri (First hardsuit (Mark II version for Eurocosplay 2011)) - Bubblegum Crisis Tokyo 2040


Ayacon 2011

Ayacon 2011: British representative for Euro Cosplay 2011

Showcased 2nd October 2011 What is this?




Having previously done a major sewing project, I decided to challenge myself to a set of armour this time. It's my first attempt at a full armour costume and the Priss hardsuit presents itself with a plethora of unique challenges so I'm again on a steep learning curve.

It is made mostly from plastazote, although the mark II version does contain some wonderflex to strengthen strategic positions as a result of problems which arose in the wearing of the mark I version.

To get the hard shell look I experimented with various coatings on the plastazote. Although latex gives good coverage and maintains very good flexibility it does leave brush marks which I was hoping to avoid, and latex also prevented me from using metalic paints. The best option was PVA, however, I found that not all PVAs are created equal with only one having the characteristics I required. (Edit Nov 2011. After several requests for the brand information, I can tell you that the brand of PVA I used for priming the plastazote is called Loxley, nothing else I tried matched it. I get it from London graphics but it's also available on-line.)

Some of the shapes in this suit will prove difficult but I am experimenting with various ways of heat forming the plastazote to get the shapes I need. In the end I went with a combination of three techniques; vacuum forming which included building my own mini-vac former, push moulding and intricate curve cutting to give the sweeping lines - I don't know how best to describe this last one, it's almost like cutting on a bias but not. All the techniques are on the mark II version hence why it'll look so different to the mark I

Edit Aug 2011:
Problems with my Eurocosplay costume meant I switched to Priss for my masquerade costume, and a very hectic three weeks followed. I was persuaded to enter Eurocosplay with it and was very surprised to be chosen as the second British representative.

So, just over two months to improve it before the finals!

Edit Oct 2011:
The progress is ongoing, pieces are becoming more intricate. The shoes are by far the hardest things to complete and are pissing me off to no end!

Edit Oct 2011:
So far approximately 80% of Priss has been remade in preparation for the eurocosplay final. There is such a difference between the mark I and mark II versions now, mainly due to gaining experience with what is possible with plastazote. I just hope it all stays together this time!

Edit Nov 2011:
The mark II eurocosplay final version of Priss is all but complete now. As ever, there a few minor pieces that I wish to either alter or change after the wear but I can add to these at a later date now.

So much changed between the mark I and the mark II versions, with most of the armour being upgraded and bevelled giving a more curvey appearence and I also altered my body shape with padding and a corset to give a more feminine figure. I am extremely happy with the results and really love how smooth all the armour turned out. This has been a difficult but rewarding project and I have gained so much experience in using and patterning plastazote for armour.

The Eurocosplay finals were great and I think I did a good job of representing the UK. Dancing in 6 inch platform boots with limited flexibility while having virtually no vision was extremely hard. Very pleased to have found out I placed 8th overall in the finals, and congratulations to Xae for winning.

Edit 2012: For those wondering about the vacforming of the plastazote that was done in this costume, see the tutorial here


k4tt posted on 14 March, 2011 - 10:15
Niiice. Glad to see there are other BGC cosplayers out there. Will be interesting to see how you get on with your construction, and how you tackle the helmet. I can't attend any events this year, so I envy you for being able to make a start and wearing it this year. Good luck anyhow ;)

theKillingDoll posted on 14 March, 2011 - 10:37
Thanks. Yes I know all about work getting in the way, rushing to complete this now. The helmet has been difficult. Still figuring out how to see out of it. Should be posting some pictures soon.

k4tt posted on 14 March, 2011 - 10:45
Can't wait to see the pictures. Did you make the helmet out of zote as well? or did you use some form of plastic/acryllic sheet? My Linna will have to be made from plastic, but my other girls I've been using EVA for the full helmets. In-between the colour joins, I've created little slits, a bit like pinhole camera technology, enough to see out of, but not enough to overly ruin the design. maybe at a later date, once I get the other girls built, perhap we can ammas a BGC group, since I know a couple of people who also want to do BGC Hardsuits.

theKillingDoll posted on 14 March, 2011 - 11:17
Yes, helmet is made from platazote. Given the unusual shape I needed to heat form it and my vac former isn't big enough. Looking at slits too, but trying to hide them, as you say, without ruining the design. I have a friend doing another BGC costume with me for minami, he's keeping it secret for the moment but its not a hardsuit.

Lulu Rose posted on 14 March, 2011 - 14:18
I don't know if this is worth a look for you, for the base of the legs. Since they look very similar to "hocks" as in, the structure of the hind legs of an equine type animal, or an animal with legs like that. she has put a tutorial of sorts up for them. Look like a bitch to walk in but it might give the desired effect, though the height boost might be too much.

theKillingDoll posted on 14 March, 2011 - 14:24
Thanks for the suggestion, although I have already acquired a pair of platform heels which I should be able to modify. I'll see how they go first.

Junta posted on 14 March, 2011 - 17:24
still can't wait to see how this turns out! s'a bugger we can't visit any time soon, as theres many things i'm curious on about how you're putting it all together and prob shouldnt completely clog your comments page with it ;)

theKillingDoll posted on 14 March, 2011 - 17:27
Thanks. Feel free to PM me with your questions, I will try and answer. I have got various photos that I will be putting up gradually.

ryaoki posted on 16 March, 2011 - 13:38
This is amazing, how on earth did you achieve all the perfect curveyness!?

Ranma1-2 posted on 16 March, 2011 - 14:03
Yeah this is shaping up realy nicely.

Junta posted on 16 March, 2011 - 18:45
Shaping up awesomely. The mini vac-former performing well then? And i shall have many questions indeed, but figure i'll wait til you're done given the timescale left to make in ^^

theKillingDoll posted on 16 March, 2011 - 18:47
Thanks Ryakoi: A combination of heat moulding and carefully joined pieces. There are some simple tricks I have used while heat moulding that have given pretty good results.

Lulu Rose posted on 16 March, 2011 - 19:29
Aww man, bummer on the second shoe. Even if it doesn't come out in Minami I'm sure you're going to do this really well. Gives yourself more time on it at the very least. Can't wait to see it though.

Ilpala posted on 22 March, 2011 - 12:23
Fantastic progress so far, real shame it didnt work out for Minami though :( Still, I'll look forward to kicking some boomer ass with you later in the year.

CosMech posted on 24 March, 2011 - 14:02
This looks amazing i'm thinking of throwing a linna in the works just for fun with her bad ass ribbon cutters :]

Sillabub posted on 27 July, 2011 - 09:35
Oh wow. This is looking awesome :D

Lulu Rose posted on 2 August, 2011 - 20:04
EXCITING! The chest looks really smooth!

Raine posted on 7 August, 2011 - 23:06
This looks so awsome!~~

Demented Kid posted on 11 August, 2011 - 00:32
That helmet looks AMAZING~ Cant wait to see this finished @_@

Alyx posted on 11 August, 2011 - 01:31
This is looking FANTASTIC!! You are doing an outstanding job!

tripletriad posted on 11 August, 2011 - 02:23
This is simply amazingggggggg!

Relion posted on 11 August, 2011 - 19:14
I don't really know the series but I just wanted to say that it looks fantastic, really professional. It's going to look amazing when it's finished!

Ranma1-2 posted on 15 August, 2011 - 12:51
WoW painted chest piece is looking the biz!

Sephirayne posted on 15 August, 2011 - 14:48
Wow! Progress is looking epic already. I'm loving the helmet and the chest piece. I love how you have it so smooth. Really looking forward to seeing this. Might have to give this method a try one day.

Manjou posted on 16 August, 2011 - 00:04
Looking forward to seeing this at Aya, more so watching you try to walk in those shoes! XD If your wearing this Saturday we can do the robot walk together XD

Lunar_Kitten posted on 21 August, 2011 - 19:37
Just heard about your EuroCosplay qualification - well done Phil! Ironic that you were hoping to enter Kilik for it but changed your mind about taking that to Aya, then carried on with this, and this won instead! Nice one :-) shame I didn't get to see it at the con but looking forward to seeing photos.

Mangamad posted on 22 August, 2011 - 14:59
Well done on getting though to the EuroCosplay Qualifications. I want to see see this up close but you keep disappearing like the real Knight sabers. XD

Chibi posted on 22 August, 2011 - 22:52
Absolutely fantastic work! Congratulations on the Euro Cosplay placement, you'll do us proud!

Lulu Rose posted on 22 August, 2011 - 23:13
You deserve it! seriously, well done.

Leolarua posted on 23 August, 2011 - 14:26
well done on winning the qualifier, you deserved it. amazing work and wonderful costume

JustPeachy posted on 23 August, 2011 - 14:35
Congratulations on your place in the Euro Cosplay :) Epic Cosplay!

Pandora-Chi posted on 23 August, 2011 - 14:58
Congratulations on the Euro cosplay!! You deserved it!! This was such a well done cosplay!! Wish you all the best x

CrystalNeko posted on 23 August, 2011 - 15:09
Massive congrats on being our second representative!! Truly well deserved, I'm impressed by just how neat the curves are. Also impressed by how you managed to walk in those heels!!

yami-no-neko posted on 23 August, 2011 - 15:57
such an awesome costume. I love the ammount of detail and dedication put into this. It's nice to see some retro (I guess that's what you says these days) costumes still making an appereance Well done, and good luck in the Euro cosplay. I hope you win.

Freyarule posted on 23 August, 2011 - 19:49
Congrats on qualifying for EC! You totally deserved it :D I'd love to hear how you vacformed everything!

Storme posted on 23 August, 2011 - 22:00
Congrats, dude! It's epic work, and you totally deserved it. :)

theKillingDoll posted on 23 August, 2011 - 22:24
Thank you everyone for the lovely comments. Freyarule: Only a few pieces of the costume were vacformed, larger parts were created by a push mould method. I'll give more detail about both methods soon.

Sephirayne posted on 24 August, 2011 - 14:03
Congrats on being the Second Eurocosplay UK qualifier. Loved your costume and the result looked so polished. Loved how it looked on stage.

Amy-Lou posted on 24 August, 2011 - 16:01
Grats on getting into EC. This is a really impressive costume, you got it looking so smooth! Interested to see how you improve it later, keep practicing that hip wiggle XD

Pez posted on 24 August, 2011 - 16:57
Really, really great costume! (And wow, how did you manage to walk in those shoes?)

Sillabub posted on 25 August, 2011 - 10:52
Congratulations on the EC heat! A richly-deserved victory for you :D

Zirco posted on 25 August, 2011 - 11:05
I really love this costume. it's even the correct colour. 2040 hardsuit is my favourite out of all her hardsuits. I like the fact that you even got the heels and the knuckles right. congratulations on your Euro cosplay qualifier place, I can't think of anyone more deserving, or better to represent UK. It made my whole weekend. I'm sure you'll win

Ilpala posted on 25 August, 2011 - 21:47
Simply beautiful work. Well done mate.

Berserk667 posted on 26 August, 2011 - 03:27
Awesome stuff! Love bubblegum crisis

Ranma1-2 posted on 26 August, 2011 - 14:32

Kacela posted on 2 September, 2011 - 20:45
This is really awesome. Congratulation on getting into the EuroCosplay!! ^^

Defrain posted on 9 September, 2011 - 09:40
awesome costume for an awesome series triple thumbs up

Manticore posted on 9 September, 2011 - 12:46
The fact that you enjoyed strutting around in those High Heels is just a uber mega bonus from me here! Amazing Cosplay dude! Congratulations on getting through to 2nd place qualifier!

Sephirayne posted on 2 October, 2011 - 17:24
Still impressed with this. The finish is brilliant. Also love that you built your own vac former. Win for the heels. Congrats on the showcase.

Lady Bahamut posted on 2 October, 2011 - 18:43
Loving your cosplay! All that armour is! *_*

ToroSonyCat posted on 2 October, 2011 - 21:15
Wow! Sooo awesome!! :D

SlimDefinition posted on 2 October, 2011 - 22:30
I remember meeting you backstage at Ayacon. That Priss hardsuit is fantastic, and congratulations on getting a place in EC. :-)

KiraraYumi posted on 4 October, 2011 - 22:58
Wow, this looks amazing!

tripletriad posted on 4 October, 2011 - 23:23
I'm so pleased this got a showcase, massively well-deserved!

Nomes posted on 31 October, 2011 - 23:33
Thank you so much for the up close and personal look. It's amazing in the pictures but OMG in real life. It's got an absolutely perfect finish. Just brilliant. And well done!

Amy-Lou posted on 1 November, 2011 - 09:45
The upgraded version is even more impressive, look at that figure! You must be so proud, it looks just like car bodywork.

Donna posted on 6 November, 2011 - 21:42
I'm gutted I couldn't see this in person... Its quite possibly the most beautiful thing I think I've ever seen.

MangaChild posted on 6 November, 2011 - 23:07
I didn't think it possible but MkII is even better!!!! ZOMG!!

zabuza89 posted on 24 November, 2011 - 16:03
that looks BADASS!! you are awesome

JWBeyond posted on 15 December, 2011 - 01:18

Tsupo posted on 20 January, 2012 - 19:31
You did an amazing job on this cosplay! Loved seeing this at Aya and congratulations. ^^

smokie posted on 29 March, 2012 - 12:58
after u painted on the plastazote with pva did u use some kind of primer like plastidip ? btw ur suit looks rellly awesome !!! im stil working on my iron man suit :D

theKillingDoll posted on 30 March, 2012 - 13:49
Smokie: Thanks for the comment I used a standard primer designed for use with car spray paints. Two to three layers before I added the colour on top. Plastidip could work but I have never used it.

Dax79 posted on 15 November, 2014 - 15:59
I've had a real good look at this... REALLY COOL! It looks so smooth, really inspiring work :) I'm taking notes!

Progress Journal

16th October 2011

Freakin' boots!

These really have been the most difficult pieces to construct of the entire costume. Not only do they have an incredibly unusual shape, but the first set I made suffered from a creasing problem which ruined the paint work.

I was never happy with my first attempt at the shoes, and after one wear further problems came to light. Seeing pictures of them makes me shudder slightly now as I knew I could do better. So I have been mainly focusing on solving the many issues that I experienced the first time around.

It has taken 12 attempts to pattern these but I finally have a boot pattern I am pleased with. Gone is the simple tube design and in comes a fully curved thing of beauty mirroring the natural curves of the leg. Also this is, in theory, supposed to float on the undershoe, but that is still work in progress.

15th October 2011

Shoulder pouldrons

These are the shoulder pouldrons in progress, which slot underneath the arm section posted yesterday. Sculpt of the domed pouldron was made from newplast and then they were vac-formed in platazote. Edges sanded down and smoothed off with interior filler, before being primed.

14th October 2011

armour 2.0

I've been working on upgrading Priss, steadily replacing pieces of armour with improved or completely different pieces. Depending on time, Priss may well undergo an almost full remake for Euro.

The previous shoulder armour was a combination of time getting the better of me and inexperience in making armour, it is my first suit after all. It has changed from a single coverall piece to a multiple piece faux hinged design which is more faithful to the original design. It also has better shape and fit.

It's still in pieces while they are prepped, but I have attached a picture of the main shoulder joint (in progress) which will then have three additional pieces surrounding it.

3rd September 2011

armour upgrade

I have several upgrades planned for the Euro finals in October, including improvements to the overall look of the armour.

I have looked at adding a bevelled edge to the armour instead of the straight lines associated with sheet plastazote. It's a little more work but the test piece I did reduced the prominent sharp edge and gave more of a curve, which I think is more in character of the design. I am also in the process of tweaking the construction method slightly to reduce wear and tear.

24th August 2011


Still a little surprised to be chosen for the second Eurocosplay qualifier place as there was some really good costumes at Aya, however, I have a lot to do to prepare the costume for October.

The first wearing of Priss revealed some technical issues which I will have to correct, the main one of these being the boots. Plan is to build a set of duct tape dummy legs to build the boots around. I need to address the excessive flexing which is causing problems as well as still being able to get in to the shoes. I have a few ideas which I need to test and I'll report back.

17th August 2011

more vacforming

I love this little piece of kit, it's really quick to produce multiple identical pieces. These are the little jets on the boots of Priss, the mould made out of sculpy and then vacuum formed in plastazote.

After Aya, I will write a tutorial on how to make and use this mini-vacformer

17th August 2011


The back armour piece has been made as well as the leg armour, although I have encountering a few problems. Hopefully I have solved these.

This is my first major armour project and I have learnt a lot while doing this costume, some of it has been very frustrating. Some things I would do the same again, others I would change, but that's what experience gives you.

Guess I'll continue and hope it stays together.

15th August 2011

Painting begins

I spend a lot of time comparing different shades of metallic blue and eventually went for one that I originally picked out a couple of weeks ago. Painting starts!

14th August 2011


Progress continues. The costume has three identical half sunken domed shapes, two on the hips and one on the back. So I created a basic mould which I then vacuum formed in plastazote using my own home made mini-vacformer. It certainly cut down the amount of time required to create three identical pieces.

10th August 2011

getting a pasting

The building up of the sealant coats continues, but I have finally done enough to spray primer on the helmet. Nice!

7th August 2011


I have done further work on the boots and the helmet. I have added the heel piece which has given a better finish at the back of the boot. I have also been smoothing some of the joins with polyfiller, which you can see in white. Once I have completed the sealant coats this will all be hidden under the primer and paint.

The helmet had had the antenna and the cheek pieces added, this also requires a couple more coats of sealant before spraying. I have also have the arm pieces constructed, and they are undergoing the sealant ritual too.

1st August 2011

foot fetish

Back to Priss after almost 4 months away, realising the reason I had to abandon it in the first place, the problematic left shoe. It appeared that part of the plastazote I used for creating it was covered in an oily substance meaning the primer wasn't sticking properly.

I have cut away the problem section and glued a fresh piece back in. Now I have to go through the priming process again. I have also filled in the gaps between the bumps on the foot to create a smoother surface for the priming and painting.

I also have to figure out how I am going to do the join between the shoes and the leg armour. The strange shape of the shoe meant it all had to be glued in place, so I could end up having to leave a small gap for movement.

5th April 2011

Filling, sanding and priming experiments

I have been doing a little more work on this costume before most of my focus goes on my Eurocosplay costume. I will continue to plod along if and when time permits.

I am looking to recreate the smooth hard suit look so have decided to stay away from using latex to cover the plastazote as I find it leaves brush stokes. Instead, I have been testing several brands of PVA glue with varying and surprising results. Most crack when the plastazote is flexed, however, I have come across one that allows me to bend it completely in half while retaining integrity. Furthermore, it also maintains with ability after it has been sprayed with primer and car spray paint which was surprising. I want to use a metallic blue for Priss so this is is ideal.

After shaping, I have primed the chest piece with PVA and then filled in the small holes and creases with crack filler and sanded, followed by further priming. I have found that it is possible to lightly sand the corners of the plastazote after a couple of layers of PVA to leave a very smooth finish. After much sanding to give a smooth finish I have sprayed the piece with paint primer.

I just have to pick a shade of metallic blue now.

16th March 2011

Fate it seems isnt without a sense of irony

Was proceeding all good and well but it appears fate didnt like that. Just experienced a big problem with the other shoe and repairing it will take more time than I have as this was supposed to be for Minamin in 2 days. So I guess I am forced to postpone the costume now.

15th March 2011


These have been difficult due to the bizarre shape. I have decided to use 5 inch platform heels as the base, then cover them with plastazote. The shaping at the front is based on a beer glass, giving the curve and bulb end I required, with further heat moulding to get the overall shape. The raised spheres are made of sculpy.

Must continue!

12th March 2011


I have completed the structure of the chest piece. It is made up of several pieces to give the rounded nature of the suit and the area it protects, and I am pleased with the results on such a short time scale.

Note to self, if I make another full armour suit, remember to give myself more time!

Now to move on to the arms and legs, as well as priming the plastazote.

7th March 2011


Managed to make some progress on the helmet. It is an awkward shape, but I have managed to form it in to a close approximation. It is made out of plastazote that has been heat formed, with a acrylic panel which will be sprayed black.

Problem now is vision. The acrylic panel is too low for any suitable view and will also be black, so I am looking at making some small, discreet holes to be able to see out of without detracting from the design too much.

1st March 2011

Making a start

This has been on my to do list since late 2009 but other costumes have taken priority. However, I now have time to give it a go.

This is my first full armour project and is more of a construction challenge/experience for me. Looking at the hard suit shows some really tricky shapes that I'm going to have to construct, particularly the helmet, the shoes and the chest.