Tessai (Rock Variant) - Ninja Scroll




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)


sjbonnar posted on 31 October, 2007 - 15:34
Dude, I will love you if you pull this off O_O I've NEVER seen it done and that's a right shame!

alexfratley posted on 4 November, 2007 - 20:22
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?

HelloKitty posted on 5 November, 2007 - 09:30
Tessai FTW! nuff said!

Haynes84 posted on 13 March, 2008 - 00:20
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 ^_^

ryaoki posted on 8 April, 2008 - 16:45
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

stripey_dani posted on 8 April, 2008 - 16:58
Ahhhhhhh another costume I cant wait to see! Ninja Scroll is ACE

MangaChild posted on 8 April, 2008 - 21:15
trust you to get the wrong idea reiss hes not a hentai tentical monster ><

ryaoki posted on 1 June, 2008 - 11:29
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

ryaoki posted on 1 June, 2008 - 12:52
omg sword progress is looking superb man

Mocha-Berrytan posted on 1 June, 2008 - 13:06
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

ryaoki posted on 1 June, 2008 - 13:21
hey mocha its insulation foam so you can get it from any DIY store, but mike will be able to give you more detail

Ikkaku-kun posted on 1 June, 2008 - 14:36
huzzah for celotex :) bet they didnt anticipate giant weapons being made out of it 8D ..

nanahara posted on 1 June, 2008 - 20:21
this will be awsome to see, always wanted someone to cosplay this guy.

MangaChild posted on 2 June, 2008 - 10:36
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

HelloKitty posted on 2 June, 2008 - 14:53
luck? 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!!

Ikkaku-kun posted on 2 June, 2008 - 21:27
Sanding??? by hand??? Bahh :P do what i did and use a power sander and no face mask xD ...... its lookcing wicked :)

Odd-One-Out posted on 4 June, 2008 - 17:00
I've never really understood how to fibreglass, do you heat up the sheets and then press it down to the shape you want?

MangaChild posted on 4 June, 2008 - 17:09
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..

Ikkaku-kun posted on 4 June, 2008 - 18:56
wooot for stinky fiberglass.... just dont get it on ure hand then itch ure hair ;) thats where i went wrong 8D

Kaka Extreme posted on 9 June, 2008 - 00:31
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!!!!!!!!!

ryaoki posted on 19 June, 2008 - 21:52
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

BlusterSquall posted on 19 June, 2008 - 21:56
When you pull this off you will officially win at everything. :D Looking completely and utterly AMAZING so far!

nert posted on 21 June, 2008 - 19:38
You have joined the have-small-statue-of-own-head clan \o/ Looking good so far!

ChibiVampireM posted on 21 June, 2008 - 23:41
Meeps the weapon making sounds complicated but looks ubar so far! I will have to poke Amber to get your secrets. :P

nert posted on 22 June, 2008 - 09:47
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..

1000014 posted on 4 July, 2008 - 00:52
ahh amazing....i wish I COULD be a Yurimaru for you -_-

behind_you posted on 9 July, 2008 - 13:10
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!

ryaoki posted on 17 July, 2008 - 17:03
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

ryaoki posted on 2 August, 2008 - 15:08
MISSION...COMPLETE good job mike

behind_you posted on 4 August, 2008 - 12:15
Jaysus man, it's complete and you've NOT put a SINGLE pic up? You're cruel, bud. Cruel XP

Defrain posted on 5 August, 2008 - 18:10
cant wait to see this at ame gotta love nija scroll looking epic mate

behind_you posted on 13 August, 2008 - 20:00
glad to see some non-blurry pics. this cos keeps on impressing. good to meet you guys!

ryaoki posted on 13 August, 2008 - 20:03
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

Kaka Extreme posted on 13 August, 2008 - 20:03
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*

Leadmill posted on 13 August, 2008 - 22:58
This costume was beyond epic mate, well done!

Odd-One-Out posted on 14 August, 2008 - 18:21
The photo with you in the darkness is great :D

Ilpala posted on 14 August, 2008 - 18:41
Truly an epic body suit, I thought you captured the whole look very well.

airyfairy posted on 14 August, 2008 - 21:49
That was one awesome cosplay :)...and thats our arm your eating :O

MangaChild posted on 14 August, 2008 - 23:06
thanks for the hand XD no pun intended :P

terandir posted on 19 August, 2008 - 11:53
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

Mtani posted on 20 August, 2008 - 01:20
Ooh! That was you??! Brilliant cosplay! =D

Amy-Lou posted on 20 August, 2008 - 19:27
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!

sjbonnar posted on 20 August, 2008 - 21:59
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!

Tak posted on 20 August, 2008 - 23:54
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

Anonymous posted on 22 August, 2008 - 19:44
I think you set the standard on LIFE :D absolutely amazing!!!!

Orihime posted on 23 August, 2008 - 06:05
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

MangaChild posted on 23 August, 2008 - 10:52
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.

stripey_dani posted on 27 August, 2008 - 14:12
Absolutely incredible! Please rewear this to expo!!!

Moozman posted on 23 October, 2008 - 15:59
I love this, im aiming to do full body if not semi body latex work myself at somepoint. Moozman

Anime_Angel posted on 29 October, 2008 - 22:23
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^__^

ryaoki posted on 7 November, 2008 - 20:01
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

Kaka Extreme posted on 7 November, 2008 - 20:22
LMAO love the new pic hahahahahhahahahahahahahahahah goes so well with the cos LOL

Defrain posted on 24 November, 2008 - 12:42
lol gotta love reiss and his out ragous photos

PKNIVES posted on 2 April, 2009 - 16:55
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!

Ikkaku-kun posted on 28 April, 2009 - 23:50
You've never looked prettier mike ;) lmfao!

RebaSephiroth2 posted on 9 February, 2011 - 17:11
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

Progress Journal

3rd July 2011

Torso 7

Back again

3rd July 2011

Torso 6

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

3rd July 2011

Torso 5

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

3rd July 2011

Torso 4

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.

3rd July 2011

Torso 3

Left and right sides of the back done

3rd July 2011

Torso 2

Further progress on the back

3rd July 2011

Torso 1

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.

3rd July 2011



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

12th September 2008

The Mask - Part 2

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.

12th September 2008

The Mask - Part 1

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 :)

8th September 2008

The Sword - In Progress 7

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 :)

8th September 2008

The Sword - In Progress 6

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 :)

8th September 2008

The Sword - In Progress 5

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...

8th September 2008

The Sword - In Progress 4

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

8th September 2008

The Sword - In Progress 3

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

8th September 2008

The Sword - In Progress 2

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.

8th September 2008

The Sword - In Progress 1

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.