So while I was going through my wife's playthrough of the trilogy (she gets super sick if she plays so I play while she listens and makes the choices), I actually got up close and personal with Chief Weyrlock Guld. I've always killed him from far away, but somehow he got close enough that I actually got to see his armor. I fell in love with the design, even though the lighting made it look pink (where as the actual color is white). I immediately wanted to make it, and expressed this want to a good friend of mine, Keelah Monster Cosplay. She mentioned that Garm, the leader of the Blood Pack on Omega, had basically the same armor set, and was covered in the group's colors and symbol, and would be much more recognizable.
I was instantly hooked. So, if anything, you guys can totally blame her for this gigantic monstrosity. ;)
(If anyone is interested in learning this program, I highly recommend starting out with masterXeon1001's Blending Away the Pain beginner course. Very informative, and it's totally free - though donate a few bucks to him for it 'cause it's totally worth it!)
Once I had enough knowledge to do what I needed, I fixed up the file, then sent it over to the ever trustworthy Pepakura Designer program. This one isn't free, but it's super useful in turning a 3D model into a physical pattern. That helped me flatten everything out to something I could cut out and trace to the foam. It also help me lay it out in a way that used as much of a foam sheet as possible to cut down on having to buy tons, and cut down on the amount of parts I had to cut out which lowered the amount of seams on the part.
Next came the fun part: cutting! There was a huge pile of paper to cut, just like with Threshy, though thankfully the parts were much larger and there were fewer of them. It still took forever getting them all ready, but it was worth it.
I used BARGE Contact Cement on this one as well, to give a much more secure hold than the DAP Weldwood does. I started with the torso section, partly because I wanted to but mostly because it was the biggest, most detailed section and I wanted to get the hardest part done first.
Got to work on the back next, which is set up in a kind of stair-step section of sorts. It kinda makes me think each section slides upward under the one above it, so that the Krogan inside can get into and out of it. We never actually see it happening, but it's a fun theory all the same. I also made the shoulder bits, which were super simple but really bring out the full look.
Of course, you're probably wondering what those empty spots are on the back and sides. Don't worry, we'll get to those. For now though, I wanted to get the entire back section done. The last bits included the lower back, and a tail.
Once that was safely stored away, I got to work on the extremities. The arms and legs were muuuuuch easier to do than the torso was, but each would pose their own eventual challenges.
So, taking my new skills with Blender and my newly acquired 3D printer (gifted to me by a family member who saw I was taking interest in 3D printing), I started designing finger joints.
Here's a video I made to demo the process:
And, thanks to having everything to the right sizing, I could finally install the frame inside the torso!
Then I went to the hardware store again, and grabbed some insulation tubing used for pipes so that I could fill in the openings in the back and a few spots in the arms.
Since that worked out how I wanted, I grabbed some more of the tubing and got back to work on the hands. I glued in the foam to the finger armor bits and cut a V in the back right where I wanted the joint to bend. I ended up cutting a small strip of foam to glue the thumb on, rather than dealing with getting it to move as well. I also cut a section of tube in half and glued it to the back of each boot, just to add a little more detail.
After I brushed that on, I got a quart can of red interior/exterior latex paint and hand brushed it on too, again mostly for cost reasons. One quart at $12 as opposed to eight or ten more spray cans at $3-5 apiece.
For the head, I got a hard hat with the intention of adding PVC pipes to it. After multiple attempts to secure them with epoxy, E6000, BARGE, and a number of other things, eventually I went back to the tried and true foam that I should've used in the first place.
Once that was all done, I grabbed the brush again and hand painted the main black sections. If I had bigger rolls of craft foam I would have given it a two layer detail, painting the black on first then the red on the upper layers, but I didn't have any. Instead, the black ended up looking like an awesome tribal paint which I think fit the look just fine.
Yes guys, I totally used fabric. :D
While this was going on, I finished up the paint on the head. I sprayed on the same ivory color I used on Threshy all over the face, then sprayed the maroon onto the crest. I let some spots overlap, since some of the bony bits meld into the flesh, and I thought that would help with the organic look. Then I dusted on a few different browns, just like with the claws on Threshy, letting some of the darker browns dust up onto the crest. I had to do this a few times, because my hand would either slip and angle it wrong, or it would press a tad too hard and ruin the look. Thankfully having to redo it gave the whole thing a rougher, grainier texture and feel, which really made it all come together.
I designed some Krogan sized rivets in Blender and 3D printed out a whole ton of them. I probably could have done the same with a dowel, cutting slices out on the band saw and drilling a hole in the middle, but I had the filament (and the printer needed calibrating anyway). I added a ton of these to the armor to give it one last pop, and filled in all the rest of the open spots on the arms. I also 3D printed some rings that I tied to the fingers with fishing wire, to give them some movement.
This build was a lot of fun, definitely easier than Threshy but still with its own challenges. I still have upgrades I'd like to do on him, but as he stands now he's already a huge success. He was a big hit at Salt Lake Gaming Con, everybody loved him, and he won me my first actual placed award as Best Master Overall! Really happy with him, other than the fact that I need about a dozen fans inside so that I can wear him for longer than an hour at a time lol. Here's the final test pics, with a few videos at the bottom of the test and of Garm in action!