Corporal Lewis - Killing Floor


Kitacon IV (2012)

Featured on official Tripwire Interactive Facebook group.




Big fan of Killing Floor and always wanted to get a group together.

Thanks to Balthier42b and Ryaoki I was able to make it a reality. First proper KF i've seen done. Hope the pictures will do it justice.

It was a slightly awkward but enjoyable costume to wear.


Alias Cosplay posted on 22 February, 2012 - 16:50
Its coming together nicely.

lycaneyes posted on 22 February, 2012 - 23:27
Looks great so far

Captain_Marvelous posted on 24 March, 2012 - 15:04
Not sure what its from but you certainly look like the refence pic alot! ^^

sjbonnar posted on 25 March, 2012 - 01:18
Dude win!

Captain_Marvelous posted on 17 April, 2012 - 15:47
Well done as always, making us all look bad XD

MasterJh117 posted on 22 April, 2012 - 14:03
Mother of mercy YES! This looks awesome, man! :D Much love for the floor that we kill on.

To-Do List

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Progress Journal

8th March 2012

Burn Baby Burn!

Flamethrower provisionally finished, however there a few things that still need doing. The trigger unit isn't sitting right and the paint job on the tank needs touching up.

8th March 2012

Straps Added + Body Fixed

Attached the secondary feeder pipe to the main body using chicken wire. Then added grey tape for asthetic purposes. I varying parts of the flamethrower were also fixed into place using contact adhesive, expanding foam, and superglue.

6th March 2012

Spacer Fitting

Spacers added and then test fitted. Very happy with how they measured up.

6th March 2012

Inner Barrel Sprayed

The inner barrel was still grey so sprayed it black to make it blend to the main body. Red electrical tape was added above it to help adhesion of the nozzle when it will be added when paint dries.

6th March 2012

Trigger Unit Secured

Secured trigger unit to the connecting pipe using cable ties carefully cut to length.

6th March 2012

Spacers Added

Spacers were secured to the feeder pipe using superglue, as well as a metal nail.

6th March 2012


Because the feeder pipe doesn't quite reach the main body of the flamethrower, some metals sections were cut and sprayed graphite to match the tube.

5th March 2012

Trigger Unit Test Fit

After modding the trigger unit has been test fitted using a some tubing. I think the top part is a little underscale, so will be looking into that.

5th March 2012

Trigger Unit

Trigger unit is based off a JG MP5 lower. Bits will me removed/added to achieve the correct look. Unit will be sprayed flat black.

2nd March 2012

Further Detailing + Test Fit

The nozzle was given a fine coat of metallic red to simulate heat damage. The feed tube was painted graphite metal. Everything was then test fitted again as I await construction of trigger unit.

2nd March 2012

Tank Detailing

The tank was given two coats of yellow paint in slightly different colours. The paint job was deliberatly roughly done to better represent wear and tear. Decal, dials and other details were added.

1st March 2012

Tank Adjustment

Bottom of bottle was sawn off to better represent the fuel tank. The expanding foam with filling out the base nicely.

29th February 2012

NBC Suit Test

NBC suit arrived, tested it with rest of kit. Helmet doesn't quite sit right so may need modifying.

24th February 2012


Flamethrower was disassembled for priming, several successive coats were added.

24th February 2012

Test Assembley 2

Parts were test fitted together again to make sure they were in right location etc, prior to priming.

24th February 2012

Pilot Flame

Using a weedkiller spray lance/nozzle I constructed the pilot flame element for the flamethrower.

23rd February 2012

Helmet, Mask + Vest

For the project i'm using a British Army Mk6a helmet with a DPM cover. An S10 gas mask with black flash proof lenses, and a DPM tactical vest.

22nd February 2012

Secondary Pipe Backup Plan

After the disaster with the cardboard tube I searched the garage for an alternative. My dad pointed out some plastic 1.25" piping he used for plumbing work. This fitted quite nicely over the cardboard tubing, it meant I didn't have to take the original pipe to pieces to recover the metal parts used. The added benefit being it now bulks out the secondary pipe to a slightly better scale.

Second set of holes drilled without issue.

22nd February 2012

Pipe Drill Failiure

Attempts to drill holes in cardboard piping produced unstatisfactory results. Holes lack definition, are uneven, and damage intergrity of its structure.

22nd February 2012

Secondary Pipe Sanded

After foam had set, excess was cut away with a stanley knife and whole thing was sanded.

22nd February 2012

Pilot Flame Pipe Connector

Added connector made from old plumbing supplies to secondary pipe. Expanding foam was used to secure pip into place as well as seal both ends. Left to set.

22nd February 2012

Tank Connector

Bulked out one of the sections of tank connector with foam strips.

22nd February 2012

Nozzle Body Finished

Sleeve was added using strip foam cut to length and glued into place. Any gaps were covered with electrical tape.

22nd February 2012

Nozzle Body

Next up was to test fit the nozzle parts together and work out where abouts they should sit. I then cut a collar out of plastic piping and added to the main body off the flamethrower. An additional sleeve of cardboard tubing was then cut for the main body of the nozzle.

22nd February 2012

Test Assembley

Once the expanding foam had set I put together the various elements again in another mockup. From this I was able to work out what size the piping needed cutting to and what do next with the flamethrower nozzle.

21st February 2012

Flamethrower Mockup

Several sections of plastic piping, cardboard tubing, and pipe insulation foam were cut to length. I then mocked up the design using the parts I currently have to get an idea of how big the weapon will be when finished. It is still missing some critical elements such as the trigger unit.

21st February 2012

Bottle Reinforced

Bottle filled with expanding foam to aid in rigidity, place holder pipe added.

20th February 2012

Project Start + Fuel Tank

After looking around to find something of appropriate scale I located a bottle of lemonade that had escaped the sonambulist machinations of Ryukredapples. After drinking the contents, I then sourced a T section of pipe from B&Q and test fitted with the bottle.