Building Doom Guy: Rip and Tear Your Hair Out


Counter to the title of this post, Doom Guy was the least stressful cosplay I have fabricated in a long time. That has a lot to do with how much I absolutely love this game and the Praetor Suit’s design. The Praetor suit was a dream cosplay of mine that I never thought I would be skilled enough to do justice, just like my Daedric armor and my Enclave armor before that.

More than that, I think that these costumes were easier, mentally, for me to build because I never forced myself to work on it. At one point I took a month long break on the armor sets because I just wasn’t feeling it. I wanted to make these armor sets the best ones that I had ever made, even if that meant rebuilding the same piece of armor over and over until I was finally happy with it.


All of the armor was created with TNT Cosplay Supply foam, craft foam, and glued together with Weldwood Contact Cement.

I tend to start a cosplay with the most fun part to build, which for me is the usually helmet, and then lose interest as I build the rest of the armor. To help avoid that I started with my typically least favorite part of the armor, the shoes.

First of all, building the boots would not have been possible without the help of EvilTed‘s awesome tutorial on platform shoes. So a big thank you to him! You can watch that video HERE if you are interested.

Changing the armor from male to female was an obvious choice to me, especially since I was building the normal male version for Zach anyways. I still wanted to stay true to the original design so the only cosmetic difference is the breastplate. I gave myself a breastplate with a “uniboob” design vs individual breastplates for a few reasons. First is that it stays more true to the original design and second because the internet would never shut up about how having individual amor plates for each breast would increase the chance that a weapon would deflect into my heart. I know, I know. It’s cosplay and not meant to be functional, BUT I want it to look as realistic and functional as possible.

Sew, We Meet Again…

Most of the time I stay as far away from sewing as possible. Anyone who has been around me while I’m working with a sewing machine never looks at me the same again. You might even go as far to say that I have a dislike for it more powerful than the blast of 1,000 BFGs. This build was no different. However, I wanted to be authentic to the design and sew the leather pieces that show up throughout the Praetor Suit. One of the other reasons that I decided to recreate these sewn pieces of the suit instead of just making them out of foam was because my Grandma had found a roll of pleather that she gifted to me that was the PERFECT color! Thanks Omi! I probably would not have gone out of my way to source an accurate material as it would have cost quite a bit.

I was able to recreate this pleated look in the pleather by sandwiching two pieces of pleather over the top of couch foam. The areas where I stitched over the pleather were very flat while the other areas were nice and puffy. I sketched out the path that I would sew on top of with a pencil before I started sewing. I then was able to weather the pleather with acrylic paints while simultaneously covering up my pencil marks and hiding stitches.

YAY Painting!

As many of you know, painting and weathering is my favorite part of a build. In my opinion, painting and weathering is the most important part of making cosplay armor. A poor paint job can make a great build look bad but great paint job can make a mediocre build look fantastic. The amount of time you put into your paint job will how in your final product.

I seal all of my armor with several coats of black platidip as a primer. Then I spray paint the desired color on the armor. In this case I did three coats of Satin, Moss Green Rustolium paints. Then I toned back the green with blacks and brown acrylics to dirty it up. From this point I dry brush my favorite metallic silver paint, Jaquards Lumineer Silver, across the top of all of the armor to give it the illusion of being metal. And finally, I will go back in with a metallic silver paint pen and add dings and scratches on the armor.

The Details Matter

The finishing touches on this costume are what really bring it together.

One of those details for this build are the small screws that the Praetor Suit has throughout the armor. Now, in the past I have used googly eyes to act as rivets and screws, but for me authenticity was a very important theme for me throughout this build. So I choose to add real screws to the armor. Each armor set has over 50 metal screws pushed into the foam.

Scattered throughout the armor are small, usually white, decals. I was able to replicate these by drawing the design onto masking tape and taping that stencil onto the armor. From there I would dry brush some white paint into it to keep it looking battle damaged and faded.

Lights! They are fun and an easy way to make armor more impressive. On this build I just found a perfect size and shape LED bike light! It took the hassle out of trying to wire up a custom circuit.

FUNCTIONAL POCKETS!!! Unless you are a cosplayer yourself who has had the pleasure of needing a handler on the convention floor, then you have no idea how big of a deal this is. It was very convenient that Doom Guy has a utility belt and I slightly modified it to be able to carry my phone, business cards, chapstick, water and a speaker for music rf to attach a mic to so people can hear you when you have a helmet on.

As I stated above, one of the pockets caries a speaker for music. Not only is it fun to have *LOUD MICK GORDON NOISES* following you around but it sets the mood for people who are nearby. Zach and I love carrying music around with us when we are in our Fallout cosplays as well. It’s so much more immersive to have your theme song playing in the background and personally it helps me get into character.

Thank you all for following and showing support for this build! It really helped keep me going and I continue to surprize myself with what I can accomplish.


Creating Trico: A Living Guardian

When I first saw Trico in the previews for The Last Guardian, I knew I HAD to recreate this gigantic, adorable creature. I wasn’t happy with the idea of just carrying around a stuffed animal though. The whole point of the video game is to interact with Trico to escape the ruins.

In the year prior, I had meet an artist (Nymbol’s Secret Garden) at the Makers Fair in San Mateo who created puppets. Not the kind of puppets that you would use for a puppet show where the puppet handler is hidden but the puppets that he created were more part of an interactive performance that gave the illusion of the puppets being alive. Inspired by what I saw, I made several sketches of how I could implement this with my own puppet. I decided on having him sit on top of my shoulders with one arm puppeting his neck, head and mouth.

I knew from the beginning that the most challenging part of this build was going to be creating his face. I was not going to be able to create his face out of the usual materials that I work with like eva foam. There were too many curves and details in his face to do that. I was going to have to sculpt and cast his face in resin. The first step was to sculpt his face. I chose to try out Monster Clay and was very happy with the results! It is a wax based sculpting material which was new to me but I found it to have a quick learning curve and had a final sculpt that I was happy with.

Funny Insert: I created a perfect sphere eye with ping pong balls. I picked them up from a local big five on Superbowl Sunday. When checking out the cashier muttered something about beer pong. Taken back I explained that, no, I was actually using them to help sculpt a giant furry puppet from a video game. He looked at me and said “Suuuuuure you are.” I don’t think he believed me.

Even after watching countless YouTube Tutorials on mold making and casting, I was to nervous about wasting money, materials and time to try it on my own. Luckily, I have a wonderful friend, Katie (Feast of Dreams), who is very experienced with mold making who generously offered to help. She suggested fast setting Smooth-On resin and silicone for the mold. With her help, my first mold turned out beautiful! The silicone shell was nice and thick and the two part resin shell separated super easily.

When the sculpt was removed from the mold, pouring the first batch of Smooth-On Onyx resin into the mold was so exciting! After two weekends of work, I was holding a perfect first pull from my first cast ever! Over all the whole experience was great, but it did not come without some drawbacks. Two days later I developed a horrible skin reaction to the casting materials that looked and felt like mild poison oak (SUPER ITCHY). I was not 100% sure that the resin had caused the reaction since it didn’t develop until two days later, so I brushed it off. Unfortunately, I learned that the resin WAS the cause after casting a second Trico face and I got the same skin reaction two days later. I reached out and developing a reaction like I did is very rare but it just goes to show that you should always be cautious when using new materials.

Disclaimer: I was wearing gloves and protective gear while handling the resin. The rash developed on other parts on my skin that were not covered, mostly my arms.

Next I dremeled his lower jaw apart from his head and dremeled his eyes out. I sanded his face where there would not be any fur. I used grey fur that was adhered with hot glue, which actually sticks to the resin very nicely. I had to glue the fur down small section by section to make sure that the fur was adhered to the cast well. The ears were created with eva foam. Once I had the fur glued down I hot glued loose fur to the edges of the material to hide the raw edges. And finally I took a electric hair clippers and shaved his fur down to the desired length.

His horns were hand sculpted with glow in the dark super sculpy. Once they were baked and hardened I took a blue acrylic paint and dry brushed blue onto the horns from the bottom and worked my way up. I didn’t completely cover the sculpy with paint because I wanted to preserve the glow that it gives off. Finally, once that paint dried, I covered the horns with a glossy sculpy glaze. Once the horns were dried they were hot glued into place. I dry brushed acrylic paints onto parts of his face and fur to add more depth of color.

His eyes were very complicated to recreate. In the game his eyes are mostly seen as pure black. But every once in a while, especially in the dark, his eyes are reflective green like a cats. I casted his eyes in green resin and then painted the black around a masked off circle to create that look. To make the eyes extra reflective, I painted the back of them metallic silver.

Trico’s body and neck were very easy to make. Basically, I just made a bunch of eva foam rings to act as a skeleton and glued fur around that. His body was also filled with stuffing and the ends were closed with an eva foam disk. His tail was sewn up with one seam, filled with stuffing and capped with an Eva foam disk.

His legs were a bit more complicated. The base was cut out of eva foam with couch foam glued to the top of that and then shaped by rounding it with scissors. Once I was happy with the leg shape, I wrapped it in more fur with hot glue. His little chicken legs were shaped with tin foil and hot glued to the foam leg. I made his claws using a sculpting material called Magic Sculpt.

Then I created layers of craft foam to cover the tin foil with that looked with scales. Those scales were then glued to the foil using hot glue. Once all four legs were completed, I painted the legs with acrylic paints. I shaved down the fur where the legs would attach to the body and attached them with hot glue.

Trico’s wings were made the same way as the legs, creating an Eva foam base wrapped in fur. I poked holes in the fur and hot glued two different length feathers into the foam base. Then the areas where the wings would be glued to the body were shaved and the wings were hot glued to the body.


And so Trico was born! I learned so much during this build. Everything about it was outside of my comfort zone. More than that, I am so blown away by the reactions that he gets from everyone who sees him.