Winter Soldier arm build! (pic heavy ^^ )

[AegidiusDesigns]

My best friend basically being the biggest Winter Soldier fan boy I know, I decided to make him a Winter Soldier arm (and eventually a full cosplay) he would be able to wear for a con in April. He also wore it to the opening night for Civil War! We unfortunately had to rush making the rest of the suit, so we want to revisit it and make it better, but the arm still turned out pretty cool in my opinion! It was a free hand build out of 1mm thick foam, which I then covered in aluminum tape to get that really chromy anodized look.



And the speed-built vest!


The only real downside to using aluminum tape is that it gets wrinkled after a while. So while the arm is very confortable and maneuverable, it needs to be repaired after a long day at a con or something. Thankfully, tho, fixing it is just a matter of putting a new layer of aluminum tape. If I could maybe find a way to protect the aluminum so it doesn't wrinkle as easily, that'd be great! I'm up for suggestions since I really don't know what I could use.



I accidentally left one of the metal pieces outside of the sleeve, so it's kind of popping out, but that way you get the idea of what the full suit looks like. Still, I'd like to get a good picture of the full suit, and I'd like to add an accurate face mask. Also, does anyone know where I can buy a proper Winter-Soldier-ish looking wig?

Hope you liked the build, I'll most likely be updating this thread with more pictures of the costume as we update it ^^

 

[Fox2814]

i have wanted to make this arm this way for so long but just not had a the time. looks fantastic. are all the pieces put on individually or do you have it attached to a sleeve of some sort? how's the mobility of your arm while it's on? sorry that's a lot of questions but i am in awe of how well that looks. i can't wait to see the costume progress further

 

[AegidiusDesigns]

i have wanted to make this arm this way for so long but just not had a the time. looks fantastic. are all the pieces put on individually or do you have it attached to a sleeve of some sort? how's the mobility of your arm while it's on? sorry that's a lot of questions but i am in awe of how well that looks. i can't wait to see the costume progress further

Thanks a lot! The arm is made up of 3 big pieces. The shoulder, the bicep and the forearm. You have to put each piece on individually, but the different 'slices' of the arm, the different pieces are all sort of glued together.


We put on the shoulder and bicep first, and then to make the shoulder holds in place, there is a strap that wraps around the torso to the other side, sort of like a shoulder pauldron I guess. (credit for the pic goes to whoever made that sick pauldron btw, just trying to use that picture as visual reference)..




So then, the bicep is connected to the shoulder, and just holds in place, and the forearm fits on like a sleeve for the forearm. So basically the whole arm is made of 3 big pieces. Mobility is okay. I can hold out my arm out about 90 degrees, put it forward about 90 degrees as well, and you can bend your elbow about 90 degrees as well. You certainly can't do this with it XD



But here is what the arm can do in terms of movement. (shame about the backpack in that pic xD we were in a rush, but I would've loved to get a PROPER shot of that)




Now granted, I sort of made a 'hybrid' arm, my own version. I didn't really like the bicep and shoulders to the movie one, so I went with bigger panels on the bicep like in the comics. And the shoulder is just sort of inspired by the film, but not super duper accurate either. I might make a proper 'replica' looking arm from the film at some point, tho... But for now, I like this one ^^

 

[Fox2814]

no I also prefer the comic book version(especially the winter solder/black widow comic) where it had a separate plates for pieces. i was also thinking when/if i do my own arm i would make a sleeve underneeath with pieces of the aluminum tape(along with a few stray wires) underneath to give it that all metal robotic look

 

[AegidiusDesigns]

no I also prefer the comic book version(especially the winter solder/black widow comic) where it had a separate plates for pieces. i was also thinking when/if i do my own arm i would make a sleeve underneeath with pieces of the aluminum tape(along with a few stray wires) underneath to give it that all metal robotic look

I think making a sleeve underneath is a really neat idea! I thought of using a sort of reflective-shiny fabric to cover the inside and outside of the elbow, and maybe just make a glove (or at least make fingertips to put on a fingerless glove like he has in the film). Need to go hunting for some fabric soon, but gotta get done with finals first haha..

 

[Fox2814]

I think making a sleeve underneath is a really neat idea! I thought of using a sort of reflective-shiny fabric to cover the inside and outside of the elbow, and maybe just make a glove (or at least make fingertips to put on a fingerless glove like he has in the film). Need to go hunting for some fabric soon, but gotta get done with finals first haha..

that would probably work. maybe try on fo the zentai suits. I believe they have them in like a metallic silver. cut off the arm and then you've got the glove and the sleeve. i also thought about attaching it with button snaps onto the jacket or undershirt

 

[kcail1]

NIce work! Aluminum tape...never thought about that. I use 5 mm foam, glue and paint. Lots of silver spray paint. I use a latex glove and silver duct tape for the hand. It's not a perfect match but my paint isn't as shiny as yours. My spandex arm is bright, but again, not as bright as yours. Very cool work. Fan boy on, from this Fan girl.

kcail1

 

[AegidiusDesigns]

NIce work! Aluminum tape...never thought about that. I use 5 mm foam, glue and paint. Lots of silver spray paint. I use a latex glove and silver duct tape for the hand. It's not a perfect match but my paint isn't as shiny as yours. My spandex arm is bright, but again, not as bright as yours. Very cool work. Fan boy on, from this Fan girl.

kcail1

Thank you so much! The thing with the aluminum tape is that it keeps the 1mm foam underneath slightly flexible which is more comfortable for the wearer than a hard shell (which would feel like an Iron Man arm or something, which isn't ideal).. The one HUGE issue with the tape is that like aluminum foil it crimples and creases when it's bent too far, which is really unfortunate but it ends up requiring a lot of maintenance after a Con. So you get the super-shiny look, but trade it off with a more fragile frame.

What is your mask made out of? It it custom made, it looks awesome!

that would probably work. maybe try on fo the zentai suits. I believe they have them in like a metallic silver. cut off the arm and then you've got the glove and the sleeve. i also thought about attaching it with button snaps onto the jacket or undershirt

I might actually try that! Or just sew a sleeve out of shiny fabric because I think that would be more cost efficient. But that's a great idea, I'll have to look into it Thanks

 

[kcail1]

Thank you so much! The thing with the aluminum tape is that it keeps the 1mm foam underneath slightly flexible which is more comfortable for the wearer than a hard shell (which would feel like an Iron Man arm or something, which isn't ideal).. The one HUGE issue with the tape is that like aluminum foil it crimples and creases when it's bent too far, which is really unfortunate but it ends up requiring a lot of maintenance after a Con. So you get the super-shiny look, but trade it off with a more fragile frame.

What is your mask made out of? It it custom made, it looks awesome!



I might actually try that! Or just sew a sleeve out of shiny fabric because I think that would be more cost efficient. But that's a great idea, I'll have to look into it Thanks

Thanks for the compliment on the mask... It's an Amazon.com purchase (neoprene biker/skii mask) that I modded with 5 mm black EVA foam, hand cut and stitched to the face. I also changed the cheek profile for the sharper angles at the cheeks by sewing down the borders. That was a pain to sew through two layers of neoprene. And I don't know how to sew professionally. I just wing it. I've replaced the foam piece twice from creases forming from use. I cut in details (like the texture of the panels) with an x-acto knife. It attaches really easy in the back with velcro. Very comfy, but it does steam up your face a bit.

My issue with my arms is the paint cracking. I'm currently working on a way to seal the EVA foam. I've tried almost everything on the RPF and it's not worked to my satisfaction which tells me it's probably me.

By the way-- I have a Jumbo Spandex arm too (great vendors of fabric on Etsy). I hand sewed it (There's a thread around here about it.) to an Underarmor shirt and drew on the plates with sharpie. It is SO Much MORE comfy/mobile than the foam arm, but the sacrifice is it looks less 3D/Screen accurate. But I'll give up some 3D for shininess, no flaking, and mobility. After all-- I'm not the actor!

Kcail1
Good luck!

 

[kcail1]

By the way... more info on The Winter Soldier:Costume Research Thread. It goes back to 2013 when CA:WS was new. LOTS OF CRAZY information there. You mentioned a fabric arm. I made mine (posted it there on that thread #636) in case you wanted to see.

kcail1

 

[Hayroon]

https://arda-wigs.com/shop/bucky-classic/ This might be your best option for a wig, although it is a bit pricy, it's based off of Bucky's hair in the movie.

 

[AegidiusDesigns]

https://arda-wigs.com/shop/bucky-classic/ This might be your best option for a wig, although it is a bit pricy, it's based off of Bucky's hair in the movie.

Thank you so much! I might consider getting this if the modded wig I got last month doesn't work out! I'll still have to try and style it up a bit, before I break down and get this wig.

Thanks for the compliment on the mask... It's an Amazon.com purchase (neoprene biker/skii mask) that I modded with 5 mm black EVA foam, hand cut and stitched to the face. I also changed the cheek profile for the sharper angles at the cheeks by sewing down the borders. That was a pain to sew through two layers of neoprene. And I don't know how to sew professionally. I just wing it. I've replaced the foam piece twice from creases forming from use. I cut in details (like the texture of the panels) with an x-acto knife. It attaches really easy in the back with velcro. Very comfy, but it does steam up your face a bit.

My issue with my arms is the paint cracking. I'm currently working on a way to seal the EVA foam. I've tried almost everything on the RPF and it's not worked to my satisfaction which tells me it's probably me.

By the way-- I have a Jumbo Spandex arm too (great vendors of fabric on Etsy). I hand sewed it (There's a thread around here about it.) to an Underarmor shirt and drew on the plates with sharpie. It is SO Much MORE comfy/mobile than the foam arm, but the sacrifice is it looks less 3D/Screen accurate. But I'll give up some 3D for shininess, no flaking, and mobility. After all-- I'm not the actor!

Kcail1
Good luck!

Thanks haha! Well, what I'm thinking of doing is basically using shiny fabric for the joints, so you can't actually see it's a two-piece arm sleeve. Put some fabric in the elbow and use some to make a glove, that's basically it. All I really need to 'perfect' this Winter Soldier arm design to me is just finding a way to keep the aluminum from creasing, but I won't try EVA foam arms or full on sleeves. That being said, as mentionned I might try to make a more screen accurate arm at some point, instead of my comic-film hybrid.

We actually used an old neoprene mask, but it was so small because I used to wear it 10-something years ago haha.. So now I think I'm going to try to make a mask for my friend from scratch using fabric, straps and whatever I can find ^^

And I actually browse the Costume Research Thread quite a bit, but it's trying to get a super-accurate Winter Soldier. I mean they share really interesting stuff, don't get me wrong but I can't browse through 100 pages of stuff haha Too impatient for that.. I'm already browsing heavily thru Cap Shield painting threads... In July when I got more time, perhaps!

 

[OnyxBird]

I was wondering whether aluminum tape would be useful for a Winter Soldier arm, so it's really encouraging to see how well yours came out!

Thank you so much! The thing with the aluminum tape is that it keeps the 1mm foam underneath slightly flexible which is more comfortable for the wearer than a hard shell (which would feel like an Iron Man arm or something, which isn't ideal).. The one HUGE issue with the tape is that like aluminum foil it crimples and creases when it's bent too far, which is really unfortunate but it ends up requiring a lot of maintenance after a Con. So you get the super-shiny look, but trade it off with a more fragile frame.

Did you use only one layer of aluminum tape, and did you consider adding another layer as reinforcement? It's been a while since I worked with aluminum tape, but I recall it being stiff enough that I'd expect a couple of layers to provide considerable stiffness without being rigid. I wonder if two or three layers would restrict the movement enough to reduce the wrinkling without completely sacrificing the flexibility.

 

[AegidiusDesigns]

I was wondering whether aluminum tape would be useful for a Winter Soldier arm, so it's really encouraging to see how well yours came out!



Did you use only one layer of aluminum tape, and did you consider adding another layer as reinforcement? It's been a while since I worked with aluminum tape, but I recall it being stiff enough that I'd expect a couple of layers to provide considerable stiffness without being rigid. I wonder if two or three layers would restrict the movement enough to reduce the wrinkling without completely sacrificing the flexibility.

Thank you for the kind words! not shown here, but I also used some steel wool on the aluminum tape to dull it a bit, works great as well. But, as I said after cons it's a pain for maintenance, and so I usually just add another layer of aluminum tape. And I guess you're right, the arm is basically stronger every time haha ^^ That said, the arm only really 'lived through' one convention, and then I fixed it, then it was worn for the Civil War opening night here in Belgium, and it's a bit more sturdy now so I haven't had to fix it again. That said, yeah, maybe 2-3 layers would REALLY do wonders to reduce the wrinkles.

Also, quick update but.. I bought silver super shiny fabric, enough to make a glove and the elbow covers Will post pictures once I get around to making the glove and the added covers.