Garrus Vakarian

Garrus Vakarian (from Mass Effect) by Chris Myles

I hand carved the scars and then spray painted the whole thing. I airbrushed in the scars, details and shadows and hand painted on the "war paint." Visor made of craft foam and a hand cut/heat bent PET strip and 2 LEDs with super glued on Objet(Eden 350) icons.

Armor:
Made from armature wire/mesh, upholstery foam, plaster, and fiber glass resin.

Since this was my first attempt at armor, I tried a hand full of different methods on each section of armor. Method that worked the best was an under form of mesh/armiture with streched foam on top. Mix (1:1ish) Modge Podge with flexable Joint Compound to make thick MP and coat foam. Light sanding, paint and distress to finish. Armor looks hard but is still kinda foamy. For really flexable armor just use foam coated with flexable glue. Light sanding, paint, yada-yada...

Lighting system has 5 channels with 8 modes (no fancy micro controllers, just a hacked LED christmas light set). 59 (49 blue and 10 for the UV face lighting) LEDs in the armor (Hooray 19 hours of wiring/soldering!)

Check out Ammnra's "How I Did It" Costume Video, his Cosplay.com gallery, and his Flickr gallery.