Food Living Outside Play Technology Workshop

1990 Shredder Costume

by R2E2 on November 6, 2012

Table of Contents

1990 Shredder Costume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: 1990 Shredder Costume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Shredder Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 2: Helmet and mask assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 3: Resin and fiber glassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4: Bondo & Sandpaper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 5: Helmet: matting, resin, prime and paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 6: Making Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 7: Jumpsuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Step 8: Finished . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

http://www.instructables.com/id/1990-Shredder-Costume/
Intro: 1990 Shredder Costume
Halloweens come and gone and here are some pictures of the shredder costume that I made this year.

This was my First time making a costume that used pepakura, resins and Bondo Auto filler.

Materals:
Pepakura file - Shredder Helmet
Pepakura file - shredder blade
X Acto knife / Craft Blade
Hot glue gun / glue sticks
Card stock
Disposable brushes
Aluminum pie pans for mixing resin and auto filler
Fiberglass resin
Fiberglass cloth
Bondo Auto Filler
Rubber filler spreader
Non slick cupboard liners
Small plastic grid
Cardboard
Card Stock
Dense poster board
Red glittery Fabric (jumpsuit/tunic)
Packing foam
Elastic
Tabi boots
black fabric (sash/cape)
spray paints, (primer, black, silver)

http://www.instructables.com/id/1990-Shredder-Costume/
Step 1: Shredder Helmet

http://www.instructables.com/id/1990-Shredder-Costume/
Step 2: Helmet and mask assembly
After you get all the pieces cut out you will need to fold them and glue them together

Image Notes
1. fold tabs
2. hot glued

http://www.instructables.com/id/1990-Shredder-Costume/
Step 3: Resin and fiber glassing
(1) Apply resin to outside let dry and repeat.
(2) Spray adhesive to inside and apply fiberglass cloth.
(3) Apply resin over fiberglass cloth.
(4) Once this all dries sand all sharp area and make smooth

Image Notes
1. disposable brush
2. (1) Apply resin to outside let dry and repeat.
3. pie tray for mixing resin and filler

http://www.instructables.com/id/1990-Shredder-Costume/
 Image Notes Image Notes
1. cut fiberglass cloth into small squares 1. (2) Spray adhesive to inside and apply fiberglass cloth.

http://www.instructables.com/id/1990-Shredder-Costume/
 Image Notes
1. dremel and sand rough edges after resin drys

Step 4: Bondo & Sandpaper

(1)Apply layers of bondo filler using rubber spatula and let dry.
(2) Sand with 80 grit sand paper and use dremel around edges and corners.
(3) re apply filler in gaps and sand.

Image Notes Image Notes

1. (2) Sand with 80 grit sand paper and use dremel around edges and corners. 1. sanded
2. (1)Apply layers of bondo filler using rubber spatula and let dry. 2. dremel these areas
3. dremel

http://www.instructables.com/id/1990-Shredder-Costume/
 Image Notes
1. (3) re apply filler in gaps and sand with a smaller sandpaper grit

Image Notes
1. I didn't completely sand this down cause I will later add a textures matting

Step 5: Helmet: matting, resin, prime and paint

(1) Hot glue non slick matting onto helmet, trimming it accordingly
(2) Apply a few cots of resin
(3) spray Prime
(4) spray whole helmet black, filling in all gaps between mesh
(5) brush on silver paint, not filling gaps

Image Notes
1. non slick cupboard matting

http://www.instructables.com/id/1990-Shredder-Costume/
 Image Notes
1. (1) Hot glue non slick matting onto helmet, trimming it accordingly
2. (1) Hot glue non slick matting onto helmet, trimming it accordingly

Image Notes
1. primed and painted

http://www.instructables.com/id/1990-Shredder-Costume/
 Image Notes
1. (4) spray whole helmet black, filling in all gaps between mesh
(5) brush on silver paint, not filling gaps

Image Notes
1. hot glued in a plastic mesh which was painted black
2. sanded and ready to prime

http://www.instructables.com/id/1990-Shredder-Costume/
Step 6: Making Armor
Arm/Leg/shoulder guards

(1)Hand drew patternonto cardboard

2) Bent cardboard accordingly to contour with arms and legs
(3)Applied coat of resin to outside. Waited and let harden
(4)applied adhesive spray to inside and covered with fiberglass cloth down fiberglass cloth and resin
(5)got glues blades on, applies mesh, and resin.
(6)Primed, black and brushed on silver.
(7) hot glue on elastic straps to wrap around arms and legs

Image Notes
1. (1)Hand drew patternonto cardboard
2. 2) Bent cardboard accordingly to contour with arms and legs

Image Notes
1. hot glue on stabilizers to hold shape

Image Notes Image Notes

1. added rim of card board around the edge 1. 4)applied adhesive spray to inside and covered with fiberglass cloth down
2. (3)Applied coat of resin to outside. Waited and let harden fiberglass cloth and resin

http://www.instructables.com/id/1990-Shredder-Costume/
 Image Notes
1. blade cut out of dense cardboard mat

Image Notes
1. (5)got glues blades on

Image Notes
1. cut and apply matting with hot glue
2. (5)got glues blades on, applies mesh, and resin.

Image Notes
1. (6)Primed, black and brushed on silver.

http://www.instructables.com/id/1990-Shredder-Costume/
Step 7: Jumpsuit
(1) Cut and sew jumpsuit pattern that I found at fabric store
(2) Attache shoulder pads and armor to tunic

Image Notes Image Notes

1. (1) cut and sew pattern 1. (2) attache shoulder pads and armor to tunic

Image Notes
1. (2) attache shoulder pads and armor to tunic
2. (2) attache shoulder pads and armor to tunic
3. Packing foam

http://www.instructables.com/id/1990-Shredder-Costume/
Step 8: Finished
Now just throw on your costume and tabi boots, wrap a black sash around your waist and throw on your cape and your ready to hit the streets. recruit your foot soldiers
and Rise!

Image Notes
1. tabi boots
2. sash
3. cape

http://www.instructables.com/id/1990-Shredder-Costume/
Related Instructables

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(Photos) by (Photos) by
Cinnamontwisties zemogm

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Comments
2 comments Add Comment

Penolopy Bulnick says: Nov 7, 2012. 9:51 AM REPLY

That is amazing! I love it, just all of it is awesome!

R2E2 says: Nov 7, 2012. 11:34 AM REPLY

Thank you! :)

http://www.instructables.com/id/1990-Shredder-Costume/