Started the build this weekend.
Here are the links I've referenced before and during the build at some point:
http://www.instructables.com/id/Alien-X ... Costume-1/
http://www.jamescamerononline.com/AlienWarrior.htm
https://www.youtube.com/watch?v=GOg1ygY1Yo0
https://www.youtube.com/watch?v=zPmP-ZSDYqg
Google image searches of "Hot Toys Alien Warrior", "Stan Winston's Alien Warrior" and "alien warrior head"
Didn't use this download link but just found it on Pilerud's thread in the RPF and figured it be useful for anyone starting a build: https://redirect.viglink.com/?format=go ... ild%20here
My son is almost 6 and 1/2 and asked to be an alien. I'm happily obliging.
He's just a few inches shy of 4 feet tall.
So plan is to make the head from insulation foam with tube details from various hoses, and plastic wire sheathing. The jaw will be cut and molded out of EVA, and I think the teeth also. Hoping to get the jaw to work. Still figuring that out.
The body will be similar details, plus soft foam, EVA foam, and whatever works. I'm trying to find a used kids wet suit to chop up and layer upon. We'll see if that ever surfaces.
Needs to be pretty forgiving durability wise since my son is not the most "careful" kid, but that's typical. (I once made him full Stormtrooper armor out of EVA and finished it as they were walking out of the house to trick or treat. First thing he does is take off running, then sits down on the curb. ACK!!! DON"T SIT DOWN!!
) So the xeno suit should be ready for anything.First purchase was the insulation foam, some expanding foam filler***, and a new retractable knife.
I had a Home Depot associate cut the foam panel in quarters for me. Barely fit in the wagon still.
First I measured out 8" x 24" panels, and sliced away. (The head dimensions I approximated to 7" x 7" x 24".)
Then on one panel sketched out the head shape, and cut.
Did the same for the rest of the panels, then on the 4 inner panels I cut the shape to hollow out most of it. I plan on the top of my son's head fitting just inside and then most of his face hidden by the neck and jaw.
After the hollowing out, I stabbed some holes along the surface where the foam will be applied. Not sure if it helps but thought it wouldn't hurt. I then used a small amount of foam and layered the panels accordingly.
I probably under used the filler foam since there are some gaps in between the panels, but it's holding great. Also that stuff is super messy and wanted to avoid getting it all over my hands and the bench. Weighted it all down afterwards.
So this morning, I checked out the stack and the foam was solid. It was at this point that I realized I had never shaped insulation foam like this. I then reminded myself that the only time I've ever whittled something is to sharpen a pencil or a small branch into nothingness. I kinda looked around stunned. I figured if it was clay I'd have no problem pushing and pulling it into shape, so I'd just have to look at it from that perspective.
First thing I did was start to round the edges of the panels. Then I drew the shape of the head along the bottom to guide the blade.
The whole time I was doing this, I was coming up with contigencies. Plastic soda bottles started looking real good.
So this is where staring at an alien warrior and drawing them our whole life plays to our advantage. The more I shaped the easier it became and I started feeling waaay more comfortable with it. I can see why wood whittling is so popular.
Here's the bottom of the head and you can see my guideline drawn in.
I'm using mostly pictures of NECA alien warriors as a reference. Just kept slicing away little by little. It goes surprisingly fast.
Ignore the used up tube of E6000, can't use that for insulation foam. Eats it away.
The forehead needs a little sizing down, then I'll sketch in the head "ribbing" and remove material there.
I would've gotten more done today but it's like a sauna in my insulated garage. Sweat and foam all over.
***LIQUID NAILS ended up being way easier and more efficient to join the XPS together!! Comes in small tubes and caulking tubes at HD, Lowe's, etc.
