Captain Marvel WIP (Pic Heavy)

[SMP Designs]

OK, I'm getting started on my version of the new Carol Danvers suit and thought I'd go ahead and throw it into the mix.

So, let's just jump right in. Like many MCU costumes, Captain Marvel is constructed in several pieces. The main part of the upper body is a vest with a clever closure system in the back. This vest fits over an undershirt that contains the sleeves. Once I had the measurements and proportions confirmed with the client, I set out to begin the pattern. Here are just a few of the many reference images I used for the torso.

Fortunately, I happened to have a form that was the same size as the client and I was able to use it to create a base by wrapping the form in plastic wrap and then masking tape. Once I had the form covered as much as I needed, I began mapping out the various seam lines needed to create the basic shapes.

Note that, at this point, I'm only working out the lines needed to make the shapes for the mockup. Once the mock up is fitted and adjusted, then I'll add in all the little detail seams - like the rounded seams on the sides and all the back details.

The tape base was removed from the form, cut apart and transferred to Swedish tracing paper.

I then cut out all the pieces and built a mock up of the vest out of some leftover cordura I had in the studio.

Again, I'm just wanting to test for fit and the right shapes and proportion. Once that's confirmed, I'll be adding in all the stretch insets, refining the lines and cutting in all the details.

Next will be to create the patterns and mock ups for the shirt/sleeves and pants. Then, all the mock ups will go to the client for a fitting.

 

[Mad Monkey]

Can't wait to see this You make amazing work!

 

[Sni9er]

from one capt marvel builder to another Awesome mate looks fantastic so far! Subbed indeed!

I found the rear of the neck quite tough to proportion properly until I dug this out of the trailer perhaps it will be of some help on your next detail pass it also has a lot of the detail line shown which is super helpful also! looks like yours could benefit from a slight tweak on that aspect, but still stellar!

 

[SMP Designs]

from one capt marvel builder to another Awesome mate looks fantastic so far! Subbed indeed!

I found the rear of the neck quite tough to proportion properly until I dug this out of the trailer perhaps it will be of some help on your next detail pass it also has a lot of the detail line shown which is super helpful also! looks like yours could benefit from a slight tweak on that aspect, but still stellar!
View attachment 977031

Fab, thanks for that! I’ve been traveling all week and will be back on this on the weekend. Will definitely look into that back section.

 

[SMP Designs]

Can't wait to see this You make amazing work!

Thank you! I also can’t wait to see it.

 

[SMP Designs]

OK, lots of travel down and lots of work later, I have an update on this project.

With the vest mock up complete, I needed to mock up the shirt to send to the client. I began by using a long sleeve t-shirt that she marked up for proportion and sent to me. I cut it apart and used it as a foundation for the shirt patterns.

The section of the shirt that needed the most pattern work was the sleeves. I drafted basic sleeve patterns from the t-shirt, but I needed them to have some shape.

So, I took the straight sleeve patterns, slashed them at the elbow and then redrew them with a curve (similar to a tailored jacket pattern.

I then assembled the shirt mock up and tested it with the vest.

The last piece I wanted to add to the mock up was a test template for the shoulder armor. I traced out the basic shape to fit the shoulder and cut it out of 2mm craft foam. I heated it and formed it over a shoulder buck so that it would fit on the mock up.

A simple pant mock up followed and all the pieces were sent to the client for the fitting.

Once I had the pictures from the fitting and notes back from the client (all fit very well except for some alterations in the sides of the vest and the rise of the pants), I was able to get started on the final patterns.

The first thing I needed to do was create templates from the final patterns for Graphic Jordan, who will be creating the cast rubber detail pieces.

I sketched all the templates on craft paper and sent him the drawings. He then scanned them, cleaned them up and created 3d models.

The pieces were then printed and prepped for molds.

In the meantime, I got to work on the soft parts of the costume. I began with the vest. Working back to front, I started by creating the 'back plate' that will cover the zipper. This piece, and most of the other main parts of the costume, was created with a muslin base. The shell was then cut in segments of blue faux leather and these segments were layered onto the base.

The red faux leather is en route and the upper section will be added when it arrives. this section will be finished and with a navy blue lining and will velcro to the back of the vest.

I then moved on to the vest sides. I needed to take the base pattern from the mock up and create the detail seams around the ribs and on the side front.

I approached this section in a similar fashion to the Kylo Ren neck. Working top to bottom, each section was cut, edged and placed on a muslin base.

Here are the sides and back pinned together. Next I'll be working up the base for the chest and the shirt.

Stay tuned!

 

[Graphic Jordan]

Glad to be a part of such a fun project with you SMP Designs.

Here's a bit of a progress update on my end. I got knee pads cast up. Here's a look at those:

Knee Pads

• Graphic Jordan
• Feb 16, 2019
• 1

I also got all the smaller bits and pieces, including the shoulders cast up, here's a peek:

Cap Marvel Update

• Graphic Jordan
• Feb 16, 2019

Everything you see above was 3D modeled in Blender and Fusion 360, printed on my printers, mastered, molded, and cast in Task 16 rubber using metallic powders, etc.

 

[SMP Designs]

OK, so lots of travel and The rest of the materials for the suit came in while I was traveling, so I was able to jump right back in when I returned.

I started by adding the red to the back panel. The main red I'm using is a medium weight faux leather. For the primary segments, the red material is being backed with headliner foam to both create the dimension needed and provide support for the rubber pieces that will be glued over them.

On the back, the red segment was cut, backed with headliner and the detail lines stitched in. The piece was then lined up to the base and tacked down with Super 77.

The next step was to add the lining. The lining for this piece was cut from navy blue taffeta and thin strips of velcro were added. It was then sewn down and turned right side out. Note that the upper red section was not sewn at this point. This is because it will be edged with gold in the next step.

The gold edging was then added to the sides of the red section and the upper 'collar' secion was added. I used brass snaps to both functionally attach the collar at the top and serve as the gold details on the back of the collar. The edge between the blue and red will be covered with a cast rubber piece in the end.

I then moved on to building out the base for the chest piece. To do this, I took the mock up patterns and cut them out of 2mm craft foam and glued them to headliner foam. The pieces were all cut out and assembled with contact cement.

The next step was to create the center grey strip that extends into the collar and the upper red segments. The center strip was made of medium weight codura that was detailed and glued to the base. The red segments were created in a similar fashion to the upper back. They were then detailed and tacked to the base with Super77. The front edges were then sewn through all layers to secure the pieces permanently.

The blue lower section was next. The shell for this section was made using the blue metallic faux leather backed with muslin. This piece was then sprayed with Super77 and smoothed over the foam base.

The join between the red and blue will be cleaned up and that area as well as the underbust/outer lower edges will be covered with the cast rubber pieces.

At this point, I needed to move on to the shirt and began with the shoulders. The base for the shoulder armor pieces was made out of the red faux leather backed with headliner. These pieces were then attached to red ponte pieces that will form the upper shoulder/raglan portion of the sleeve.

The outer sleeve stripes were next. The outer sleeves were made of the primary navy blue faux leather. To make the stripes, I cut a strip of the blue based on my pattern and added gold edging to it. This was trimmed to account for the .25" gold stripe and the .5" seam allowance. The entire piece was then mounted to headliner foam. I added the foam to this section of the sleeve as I want to ensure that any area that has a rubber piece glued to it is fully supported.

Muslin bases were then cut for the outer sleeves, the stripes attached to them and the rest of the outer sleeve pieces finished with navy faux leather.

The under sleeves were made of the metallic blue accent material with a strip of stretch added to the back for added mobility. For the elbow sections, I simply cut strips of the stretch material and ran lines of pin tucks along them to create the 'ribs'.

The sleeves were then assembled and the shoulders added. Next, the body of the shirt was assembled in the navy stretch and the sleeves attached. The shirt will be hemmed, a small finishing will be added to the neckline and the temporary zipper will be replaced.

Here are all of the pieces at this point pinned together on the form.

Meanwhile, as I've been working on the suit, Jordan has been hard at work on all the cast pieces.

To give an example of how close he was able to get to my original paper templates, here's one of the finished pieces with the paper template up against it.

I also wanted to highlight the shoulder pieces. These pieces were printed, molded and cast flat. Then, the rubber casts were pulled early and molded over a form to create the curve. When the rubber finished curing, the piece held it's shape. We went with this method to control the thickness of the pieces and simplify the molding/casting process. That would have not been possible had he modeled and printed curved pieces.

There were several pieces that needed to be gold, red, and blue. All of the pieces were cast with gold powder and the red and blue segments were painted for a closest-match to the fabrics. Airbrushing and distressing/weathering smooths out any small inconsistencies at the end.

 

[Kureigu]

Incredible. Can't wait to see the finished article!

 

[thejakemoore]

Oof! This is absolutely amazing! I love your work so much! I'm almost stable enough to get back to the Red X project we talked about last year!

 

[SMP Designs]

Incredible. Can't wait to see the finished article!

Thank you! It'll be wrapping up this week and I'll be posting the final updates.

Oof! This is absolutely amazing! I love your work so much! I'm almost stable enough to get back to the Red X project we talked about last year!

Thanks man! I'm ready to pick back up on the project when you are - you know how to find me.

 

[Shanks25]

Looking so good!

 

[Sni9er]

I've been a little off the radar past couple weeks while away in Texas but damn this is IMPRESSIVE work! hats off to you and Graphic Jordan I love that guys work!! and so damn fast!!

such beautiful progress!!

 

[SMP Designs]

I've been a little off the radar past couple weeks while away in Texas but damn this is IMPRESSIVE work! hats off to you and Graphic Jordan I love that guys work!! and so damn fast!!

such beautiful progress!!

Thanks man! I'm loving what you guys are doing, too. That's going to kill when it's done.

 

[SMP Designs]

OK, so, I'll finish up the rest of the write up soon, but this happened last night.

 

[Sni9er]

I saw this earlier on Carol corps I'm SO happy for your team !!

 

[SMP Designs]

I saw this earlier on Carol corps I'm SO happy for your team !!

Thank you! We are all thrilled, not only with how it turned out, but also the response it’s been getting. Makes all the sweat, late nights and craziness worth it.

 

[dharma]

what an amazing work!!!! Congrats. It is really good looking suit

 

[Shanks25]

Do you take comissions? And would you consider doing the Male Starforce Version?

 

[SMP Designs]

OK, here's the finish to this story...

While waiting for the cast pieces to arrive, I got started on the pants. I made a general pants pattern and then attacked them front to back. I decided to make all the details on the front of the legs like a giant patch that would then attach to the base muslin 'lining'.

Once the front panels were complete, they were attached to the base and the rest of the pants were built out.

Here's one side of the pants complete and the finished pants on the form.

I then got started on the accessories - gauntlets, greaves, belt and pods. All of these pieces were created by layering segments of 2mm eva foam on top of headliner foam foundations.

The layered pieces were then covered with the red faux leather and details were stitched down to keep the edges crisp.