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COSTUME CRAFTS

This page is a collection of Nick's costume crafts that he has built.  Techniques used include dying, use of thermoplastics, aging and distressing, and faux paint treatments, and sculpting.

Please click on the pictures for a larger view.

"CROWN" ROAST

Crafts Class - Ohio University (2020)

The assignment was to create a crown, but I decided to put my own spin on it to make a faux food/crown mashup.  The result was the Crown Roast!  The base of the crown is EVA foam that has channels carved into it using a Dremel.  The bones are scraps of poplar that were roughly shaped and adhered to the crown.  To create the meat look, I used clear liquid latex and tissue paper to build mass and texture, then painted it with acrylics.  The potatoes are carved insulation foam, also covered in latex and tissue paper.  To create the seasonings on top, I soaked different coarseness's of saw dust in green and brown paint, then sprinkled it onto the crown with a fresh coat of clear latex to make it stick.

Crafts Class - Ohio University (2019)

This Corinthian Helmet is constructed entirely out of EVA foam and Worbla.  I started by making a block of foam out of insulation foam  that was roughly the size and shape of my head.  From there, I patterned the dome of the helmet using plastic wrap and masking that.  This allowed me to make pattern for the EVA foam that I was confident would fit my head.  I assembled the dome from foam and made a paper pattern for the face plate that was proportional and fit my face.  I then used that pattern to make the foam version and used contact adhesive to connect it to the dome.  The flare on the back was created in the same way.  Then, I covered the helmet in Worbla to stiffen it.  The plume on top of the helmet is EVA foam that I textured with a sanding drum on a Dremel.  All of the added detail is EVA foam as well.  One it was all constructed, I coated the helmet in Plasti-Dip to seal it, and then primed it.  I then used metallic spray paints as a base layer of color and distressing.  The final treatment was achieved by using washes and stippling of acrylic paint.

EVA FOAM CORINTHIAN HELMET

EVA FOAM GAUNTLET SWORD

Crafts Class- Ohio University (2019)

This gauntlet sword (also known as a Pata) is constructed nearly entirely out of EVA foam and Worbla.  To start, I made a stuffed version of my arm to pattern off of so that I knew this would fit my arm in the end.  I then used my research images to pattern the forearm portion and the dome of the gauntlet sword.  In order to make the blade, I welded an 1/8" rod as the core of the blade to a rounded 1/8" rod that matched the interior curve of the dome which covered my fist and then ran up both sides of the forearm part.  This ensured that the blade would not flop around and break the illusion that it's steel. I then layered EVA foam on it and shaped the blade using a belt sander and heat gun.  I covered the fist dome in Worbla to hide seams and to ensure that it would not deform while being worn.  After that was assembled, I primed everything and painted it silver with spray paint.  All of the applique detail was made from fabric lace, which I painted gold as a highlight before applying it to the gauntlet.  The handle that runs across the fist area is a dowel rod that has been screwed in through the dome, and the star shapes hide the screw heads.  I made the forearm strap out of a metal drawer handle and modified the mounting brackets by creating a steel ring that the drawer pull could be hooked into.  To achieve the aged metal look, I used a variety of spray paints and acrylic paints in washes.

THROWING KNIFE IN CHEST ILLUSION

She Kills Monsters - Ohio University (2020)

The goal of this project was to create the illusion that a character had a knife thrown at them, then it suddenly appeared sticking out of their chest due to the staging of the scene.  To accomplish this, I disassembled a rat trap and built half of a dagger which was mounted to a plate hidden in the actor's costume.  The trigger mechanism is a bicycle brake line that runs through the actor's sleeve to a squeeze brake.  When squeezed, it pulls a pin to release the half dagger to stick out of the actor's costume. Please go to the Moving Props Videos Page to see this prop in action

WARTHOG HEAD MASK

Props/Costume Crafts Class Project- Ohio University (2018)

I built this warthog mask by first starting with a pattern for a donkey mask.  I made a mockup from foam, then modified it by cutting and pinning until it resembled a warthog.  From there, I cut the face in half down the middle and created paper patterns from the pieces of one side of the face.  This was to ensure that my final pieces would be clean and symmetrical.  After I had my paper patterns, I cut my final pieces out of reticulated foam, pinned it together, and stitched all of the seams.  The tusks are microcel foam that I carved and coated in China silk.  Once the head was stitched together, I dyed the foam a dark brown to match my research images.  I achieved the final paint treatment by using Design Masters spray paint and attaching faux fur to create a mane and eyebrows.

DISTRESSED PULLED WOOL HAT AND CLOTHING

Costume Crafts Class Project- Purdue University (2014)

As a final project for a costume crafts class, I created this murderous woodsman character.  The hat was a wool blank, which I wet and stretched to be the correct size and stitched the brim for strength.  I then used various distressing and aging techniques to make it work for the character and to age the clothing.  Please see the "Human Tooth Necklace" project on this page for details on how I built the necklace.

HATCHET IN THE HEADBAND

Crafts Class - Ohio University (2020)

To create this project, I used a pre-existing headband as the base structure, then built a lightweight hatchet out of EVA foam.  The head of the hatchet is covered in Worbla to help it look more like metal.  The whole piece was painted with acrylics and spray paint.  It is meant to create the illusion that a hatchet is stuck in your head while wearing it.

POST APOCALYPTIC ARMOR AND ACCESSORIES

Personal Project- (2015)

I built this costume for a post apocalyptic themed party.  The armor is made from actual tires that I cut and bolted together to create a plate armor look.  The clothing was all purchased new, which I then distressed.  The bag was built from canvas drop-cloth and is completely functional despite it looking quite rough.

"HUMAN" TOOTH NECKLACE

Costume Crafts Class Project- Purdue University (2014)

This necklace was an accessory for the murderous woodsman character seen in my post "Distressed Pulled Wool Hat and Clothing".  The teeth are made out of polymorph plastic that I heated in warm water and mixed with an off-white acrylic paint.  As the polymorph plastic began to cool and firm up, I used a paperclip to sculpt the detail into the top.  Other acrylic paints were used on top of that to create a variety of finished and grim on the teeth.

PLASTIC HELMET FAUX FINISH

Personal Project (2015)

I challenged myself to take a clearly plastic army helmet and see if I could give it a more realistic finished. I started by adding texture to the helmet to more similarly match the actual army helmet that I had.  From there, I layered greens and browns until I had a decent color on the helmet.  Then I distressed it and added some blood spatter.  I went for a darker and dirtier look than the actual helmet.

FOSSHAPE HELMET

Costume Crafts Class Project- Purdue University (2014)

This helmet is a base of Fosshape with Sculpt or Coat on it to make it firm.  Then, the entire outside is covered in aluminum duct tape to give it the metallic look.  The rim and support strips are Wonderflex that is covered in the tape and riveted on.  To make the chainmail, I finger-wove string and then faux painted it to appear like rusty metal.   The cross is polymorph plastic with a metallic paint treatment.

HORROR CLOWN MASK

Personal Project- (2015)

I created this mask inspired by the TV show, American Horror Story's, Twisty the Clown character.  I first sculpted the mask with clay on a plaster lifecast.  I then made a mold out of silicone caulk and a mother mold of plaster.  I cast the mask itself out of body filler, resin, and fiberglass.  The paint treatment is a combination of acrylic paint and spray paint.

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