Deathstroke Costume Build – Part 3

The thighs are made from one solid piece of foam. The seams are kept together with Velcro reinforced with hot glue. They have a tendency to peel off without reinforcement. If I were you, I’d learn from my troubles and add some straps that loop around a belt. That way they won’t slide down your thighs like mine do. I wrapped the right leg in a holster, which kept the leg together and stopped the Velcro coming undone. I would recommend something else to wrap around the left leg just so that you can rest easy knowing it won’t be coming off anytime soon at a convention… or whatever else you’re planning for this outfit.



The finishing touches were painting some old paintball gloves that I had. These I painted fully orange to match Deathstroke’s. IMG_20160613_193257.jpg


At this point, I had completed the torso. Here is it fully assembled, along with a picture of the elastic straps. That allows the front chest section to move independently from the rest of the torso. By squeezing my head through the top shoulder straps, I only need to close the torso around me using some more Velcro.




Deathstroke Costume Build – Part 2

When the deadline to Comic Con quickly approached, I sped up the process of building my Deathstroke costume. Like the helmet from Part 1, the rest of the outfit was made using the same EVA foam aside from it being much thinner than the standard 1cm width. The majority of the suit was made using templates from a very dedicated modeller who created their own Pepakura files and uploaded most of them on Etsy. Go support their hard work here!

To finish up the helmet, I added the missing side and marked off one side to prepare it for painting. I used a spray initially, but this simply soaked into the foam. I didn’t have enough time to plasti-dip the armour and let it dry for a week which would seal the foam and allow painting, so instead I used a brush applied paint. This bright orange paint thankfully stuck to the armour perfectly. Painting some small lines of silver to represent scrapes where some of the foam creases were helped make the helmet look more realistic and weathered.


Next I made the shoulders. On sections of it I cut and flipped the foam to use the texture on its reverse. For the iconic shotgun shells on Deathstroke’s left shoulder, I stretched a rectangle of very thin foam over the shoulder-plate to represent the strap. I then cut 6 pieces of 1.5cm wide PVC pipe into 7cm sections. I wrapped these each in more thin foam, and stuck them to the shoulder. These were then painted red with a gold trim using acrylic paint.


The torso is made of two main sections. The upper section is joined to the lower section with elastic in order to let it move when I sit down or twist my waist. The front armour is joined to the back armour with more elastic straps and foam.


I made the gauntlets based on the design of someone else’s Deathstroke build. I did end up making these too small, so learn from my mistakes! The gauntlets were made from four pieces of foam, with some thin foam wrapped around to create the raised details.


Here’s the shins… not much to them except two pieces of foam glued together. The inner edges are curved so that when they come together they form a concave shape. Just gluing a series of straps to the back and painting the orange top finished these off.


Deathstroke Costume Build – Part 1

Greetings all.

This is part 1 of my Deathstroke helmet for cosplaying at MCM London Comic-con. Fisrtly I used a Pepakura design for the helmet (software I highly recommend if you haven’t seen it already). Those familiar with the software will know what comes next but for everyone else, here is the process…

So I began with printing onto paper various pieces that the helmet requires, and then cutting them out to form paper templates. After this, I got my hands on some EVA foam (amazing material!) and began to trace the template designs onto the foam.


Next is the most exhausting part – cutting out each bit of foam with a blade so that all of your carfully cut templates are now in foam form. Unfortunatley, I don’t have a picture of all of the foam parts before assembly, but this is an important step because I made a big decision. There are many concepts for Deathstroke’s helmet, but the main two have either the whole of his helmet completely smooth, or the right side of his helmet that covers his missing eye is raised with bumps that are meant to look like carbon fiber. I chose to turn the foam over on the right side of the helmet before cutting, because the underside of EVA foam has a great pattern that looks just like Deathstroke’s design. After using a hot glue gun to glue all the pieces together, this is the current result:


The only downside with the texture on the right hand side is the inability to create a second eye-hole, and anything you use to cover that hole such as a bit of transparent plastic or even some netting won’t match the texture, and so will be very obvious that you’ve got a second eye hole

Hmm… looks like I’ve got a decision to make. I can either cut a right-eye slit and see with both eyes, or leave the helmet looking nice and smooth and risk falling over. Or I could just take the helmet off while walking. Yeah, that sounds good. That’s it for part 1. Next is creating the back part and strapping.

Thanks for reading!

Deathstroke’s swords and sheath – Start to Finish

Time to give my Deathstroke cosplay an arsenal!

Looking at various reference images, I set about creating Deathstroke’s iconic sword(s).


Others out there have used PVC pipes, heated them up and then flattened them to create the sword, but handily I had some thin PVC pipe that is designed to hold electrical wires throughout the walls of a house, so I didn’t have to squash a PVC pipe. I cut the end of the PVC pipe off at an angle just over 45 degrees. From the side it gives the impression of a sharp blade, but from the top you can see it’s hollow. I made sure to file the end to be rounded. Yes it’s a sword, but only for show… There’s no pointed ends on this thing!

Sword 3

Sword 2

Next I wrapped the handle section of the sword in orange foam, and then set about drawing a design for the black part of the handle. I cut out the small sections of the design and then wrapped this over the orange foam so that the orange was visible through the patterns in the black foam. All I used for sticking the layers of foam to the PVC was hot glue from a hot glue gun.


Sword 1

Behold, a very cheap and easy prop sword. It’s extremely lightweight but still looks fairly realistic.

But there is one more thing to create, and that’s a sheath for the sword…

Sheath Reference 1

I planned to sandwich the sword between two layers of foam, and then surround the sides of the swords with two more layers of foam. Firstly I traced the size of the sword onto the foam to make the area where the sword will sit tightly inside the sheath once it’s inserted.

20150803_005134   20150803_005120

Next I cut out the outside of this frame. I repeated this process twice to end up with two of these pieces. These make up the sides of the sheath.


One of the final steps was to add the top layer onto each side piece. You can now see where the sword fits inside the foam. Finally I placed these two parts together, although I used Velcro so that if the sword ever gets stuck inside the sheath, it can easily be taken apart.

Sheath 1

Sheath 2