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My Old Captain Rex Build Thread
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kpresseault ()
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Joined: 24 Feb 2013
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PostPosted: Tue Sep 12, 2017 6:00 pm    Post subject: My Old Captain Rex Build Thread Reply with quote

Hey Troops!

Over the summer I began building an Old Captain Rex from Star Wars Rebels. Originally it was just for kicks and giggles... but since I really enjoyed it and learned a TON, I figured I would pass along what I learned here.

And if I can get this costume approved then that's an added bonus Smile

Here's a pic of the finished costume with Venessa Marshall, voice of Hera from Rebels. She loved it Smile

https://photos.app.goo.gl/CiMTxVSAvC4hOuvY2
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 6:20 pm    Post subject: Reply with quote

So the first thing I had to do was find a pepekura file since I had decided to try this costume project by making my armor myself. I thought this would be a lot more fun Smile

After a few Google searches I found this one that I thought really hit on the animated Rex from Clone Wars.

https://photos.app.goo.gl/qxqC09xR08ifMeRE3
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kpresseault ()
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Joined: 24 Feb 2013
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PostPosted: Tue Sep 12, 2017 6:30 pm    Post subject: Reply with quote

After finding the good file, I began to cut out the foam pieces. This was a slow process... but thankfully the pieces were not all that complicated and were pretty simple.

Here is the cut out shoulder bells.
https://photos.app.goo.gl/dCVLdGJmSm4xt9N92

Thankfully, I didn't need to make the whole armor... just chest/back plates, fore arms, hand plates, belt and holsters. For the boots, I didn't use the file because the cartoon boots don't look anything like the clone calves.

Here's what they all looked like when I put them together.
https://photos.app.goo.gl/P3PR8UPCIpsgNRMX2

https://photos.app.goo.gl/NyDjaUWj4xDuaYkh1

https://photos.app.goo.gl/h2H8T7Wy3pxIMkvl1

https://photos.app.goo.gl/NXdh5FUH8h6yjFRB3

https://photos.app.goo.gl/NjRRnGeBxjtDOn2O2
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kpresseault ()
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Joined: 24 Feb 2013
Posts: 23

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PostPosted: Tue Sep 12, 2017 6:36 pm    Post subject: Reply with quote

Next came the heat gun!

I spent quite a lot of time heating everything up with the heat gun in order to smooth out the foam as much as possible in order to minimize the amount of sanding that I would have to do.

Here's a pic of the chest/back after going through this process.
https://photos.app.goo.gl/pv644fjb9Zfr3F5A3

The heat gun was GREAT for shaping the boots. I've order animated clone boots... still haven't received them... so I had to temporarily use my TK boots.
[/img]https://photos.app.goo.gl/cXoXHS1aCZpnlEAJ3
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 6:40 pm    Post subject: Reply with quote

Next up was shopping for some baseball pants and a shirt. I've seen other costumes of Rex and the pants were pretty baggy... I really wanted a good tight fit like we see in the show.

https://photos.app.goo.gl/D5LwN7OjZRqgy5Lw2

Later the shirt would be trimmed so that no black would be seen around the neck under the armor. If you take a good look at Old Rex... you never see black there.
https://photos.app.goo.gl/N8YEXIwUcda9LNjJ3
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 6:42 pm    Post subject: Reply with quote

I wasn't happy with the color of the pants so I dyed them.
https://photos.app.goo.gl/teW6WQ9PLIbgxdkx2

If you're going to dye 100% polyester make sure you get the right type! I had to boil the pants on the stovetop for 30 minutes. Made for a nice yummy soup Smile
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 6:49 pm    Post subject: Reply with quote

Next was the REALLY fun part! Two part liquid resin to make the foam good and hard! I used a product called Smoothed On (I think that is what it was called...)

I would only have about 1.5 minutes before the resin became too hard and gooey to work with... so I had to paint it on like crazy!



https://photos.app.goo.gl/pXXWryxA9Im9r5fj2

https://photos.app.goo.gl/vsXrZ9c56vCJzWef2

https://photos.app.goo.gl/eZJ37J9cH1GZAbOi2

After doing 2 coats and everything was good and dry, I began filling in any gaps and cracks.

https://photos.app.goo.gl/bsFA2Hzv61xa1VDE2

I gave this a good 24 hours to dry... then I spent the next couple of days sanding everything to get it all good and smooth.

https://photos.app.goo.gl/2iMv9N2BMWoaxYpg2
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 7:02 pm    Post subject: Reply with quote

Once I was finally happy with getting all the gaps and bumps sanding down, I began to prime all the pieces grey. Then sprayed everything white. I went with a matte white to keep the shine down in order to help with the weathering.

https://photos.app.goo.gl/EitTRgNEpSZsWGHR2

The white paint ended up highlighting where I could have continued to sand and work on the gaps... so I did another coat of filler and sanding... and then used the remaining imperfections to show damage/weathering in later painting stages.

https://photos.app.goo.gl/Twv6lT88veq5k1GO2

Now it was time to begin the details. Depending on the picture or the other costumes I have seen of Old Rex, the weathering of his blue on the armor have different levels of stress... I LOVE the really weathered look, so I wanted that to show...

I used toothpaste that I painted on with paintbrushes to make my battle damage and scoring...
https://photos.app.goo.gl/TmxbDCZDIazBPzS62

Once it was dry I spray painted the parts blue. When the paint was dry, I used a damp sponge to remove all the toothpaste.
https://photos.app.goo.gl/wXWRbFAwQRZnq9lx1

Next was the weathering. I used a watered down black acrylic paint. I had about a 2 part water, 1 part paint mix. I used a damp sponge to apply it.
https://photos.app.goo.gl/e1F5BlRQxTkjMc6V2

https://photos.app.goo.gl/R2UUaIzjr9d5stgo1

https://photos.app.goo.gl/4EamJz7fP5atSDBi1

https://photos.app.goo.gl/69zN2kGKSxUKcdf83

https://photos.app.goo.gl/uSEnfdU9V7u73pxM2

https://photos.app.goo.gl/YG3RK2kaEdxNPB7k1

https://photos.app.goo.gl/NuwneEr0q4eMpHYy2
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 7:06 pm    Post subject: Reply with quote

After the weathering was dry, I did a white wash over all the armor pieces in order to help blend it all in.

https://photos.app.goo.gl/05ixEW19Y27moafU2

https://photos.app.goo.gl/WE6YIfAvzpWfB64T2

And the final part of the build was to sew on the knee pads. This was done by cannibalizing an old grey tshirt I had Smile

https://photos.app.goo.gl/gd4XZ1FzteCjyAau2
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 7:13 pm    Post subject: Reply with quote

I still haven't received the clone boots... so I simply used my TK boots to head out to Toronto for FanExpo (August 31-Sept 3, 2017)! I brought my TK and Old Rex for the event... and never took Rex off! He was a huge hit with the crowd. Kids LOVE Rex! I tried my best to keep a good accent going to play it up to the kids Smile

I added some face paint to my beard to complete the look Smile

https://photos.app.goo.gl/aRppQBTD075vkaGd2

https://photos.app.goo.gl/Zkfte1xSU9FgLUAU2

https://photos.app.goo.gl/yALqMusKzhgrdMgG3

https://photos.app.goo.gl/DEu5NKLEqD2kbqyk1

https://photos.app.goo.gl/aRP0UfUcsZRDazCF2
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kpresseault ()
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PostPosted: Tue Sep 12, 2017 7:15 pm    Post subject: Reply with quote

What's next???

Still waiting for boots!

And I'll probably redo the legs. They could have been a been taller to show less of the knee pads.

All in all an incredibly fun project. If it gets accepted into the RL, cool. If not, it's still a blast to wear and have a ball at cons Smile So glad I gave this a shot.
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TFS (Tom Schobert)
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PostPosted: Tue Sep 12, 2017 8:22 pm    Post subject: Reply with quote

Outstanding! Everything looks great! You've given me some ideas to update and improve my own Old Rex. Very Happy
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kpresseault ()
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PostPosted: Wed Sep 13, 2017 7:28 pm    Post subject: Reply with quote

TFS wrote:
Outstanding! Everything looks great! You've given me some ideas to update and improve my own Old Rex. Very Happy

Thanks!
Hopefully, if I ever get my Clone boots, I'll submit the costume for approval Smile
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Schraeds (Matt Schraeder)
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PostPosted: Thu Sep 21, 2017 4:45 pm    Post subject: Reply with quote

2 questions.

1) Is there a Costume Standard for this, or do you just submit reference pics with your approval pics?
2) Do you need the beard or can you do a helmet-on version?
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TFS (Tom Schobert)
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PostPosted: Thu Sep 21, 2017 7:24 pm    Post subject: Reply with quote

Schraeds wrote:
2 questions.

1) Is there a Costume Standard for this, or do you just submit reference pics with your approval pics?
2) Do you need the beard or can you do a helmet-on version?


This is not my judging category, but as I have done this costume I will suggest that reference pics be submitted in lieu of a published Costume Standard. There are several WIP's that are very helpful. The "Rebel's Rex" costumes have all been submitted with the costumer wearing a white/gray beard. Mine is natural, but I suspect some have been prosthetic. It's probably the most iconic feature of this costume. A helmet is not required, and my PERSONAL opinion is that while it would be a nice extra feature, it would not take the place of the costumer wearing a beard that resembles the character.

All that being said, we need to have a Costume Standard for Rebels Rex, especially with a new costume variation arriving in the upcoming season. I'll get to work on it.
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