Category Archives: Chewbacca

Not in the face!

One of the most important aspects of the Wookiee is the face… it’s yet an other technique, in which one can get carried away.

For our builds, we were using these fiberglass skulls. It’s just a half skull so we needed something in the back. With Target closing in Canada, we managed to get skateboarding helmets for cheap, we cut part of them off and riveted them to the skull. We also had to cut the eyes and jaw out as it was one solid piece.

We then attached aluminum strips and riveted the top and jaw to them to give it the articulation we wanted. I then sewed on some more mesh and attached that to the back so we could give the wookiees their nice hair

Attaching the jaw and helmet

Attaching the jaw and helmet

Once all that was done, it was back to punching the hair in the silicone face. I think I went a bit crazy with the punching as my face ended up looking like a muppet. However, I’d rather have more and trim it than not enough and have to detach the face once it’s glued on.

More punching

More punching

Even more punching

Even more punching

Too much punching?

Too much punching?

After finishing all this punching, I had to attach the skin to the skull. First step was to burn all the fur that extended through the mask to give it a smoother texture to glue… This also helped keep the fur in place.

Burning the fur in the back

Burning the fur in the back

I then used a gasket maker… this tar looking rubber sealant… it’s messy… really messy to glue the face on. Luckily I didn’t get any on the fur.

Next problem was… WAY TOO MUCH hair! I was unfortunately running out of time as I had a press conference to attend the next day. I tried combing it, placing it with heat and using hair spray.

Hair styling is not my style

Hair styling is not my style

Unfortunately… at the press conference… it looked like my face melted.

I'm Melting

I’m Melting

The next day, a friend suggested a product called Got2B… it’s a glue for hair. I started spraying it on and it worked great. But I still had too much hair. So a friend and fellow cosplayer, who’s a hair stylist by day, stopped by the booth and gave Chewie a trim… This worked wonders and I’m ALMOST happy with him.

Trimmed wookiee

Trimmed wookiee

Things left to do is attach the fishing line under his chin a bit better to give him an actual chin line. I want to trim a bit more. I also surprisingly have to add more hair on the sides and back to cover my neck some more.

Other than that.. he’s a cute wookiee

These legs are made for walking

Working on the legs was an interesting part of this costume.

We had bought 15″ dry wall stilts. The first problem was that the stilts’ feet were tiny… there was no way we could balance ourselves on these, let alone attach the toes.

So Luc cut out some plywood that we shaped into a front part and back part. This would give us the flex needed when walking as well as ample surface.

I then went and sealed them to prevent any damage if they got wet. Once dry, we bolted these into the stilts.

Next up, stilts are very skinny… Wookiee legs are not. We got some upholstery foam and wrapped the stilts in a way that our own toes wouldn’t stick out. The foam was held in place with tons and tons of tape.

Filling in the leg

Filling in the leg

Once happy with the shape, I sewed some mesh into a leg warmer, where we could latch the fur. We also attached the wookiee toes to the foot with more tape.

Adding fur to the leg

Adding fur to the leg

I then tried to suit up and I noticed the pants were caving in where the stilts were. So based on an other Garrison member’s build we added a metal frame, drilled holes in them and attached elastic straps.

Leg support system

Leg support system

I added these straps by stretching them first. This way, if I step forward and the elastic relaxed, it wouldn’t be all loose and cause more caving in.

Ottawa ComicCon 2015

An other Ottawa Comic Con has come and gone.
This year I made my Chewie costume for it and have to say it was the most fun I’ve ever had in any costume.

I stood in our photobooth, I wondered the con floor and met Peter Mayhew, the actor who played Chewbacca.
I also got the chance to attend the OCC Press Conference at City Hall.

It was a blast!

Testing the wookiee

More work on the wookiee.

I’ve been spending most of my waking moments (minus those stuck at work) latching

I was testing the shirt to see how the grey looked

Testing the shirt (front)

Testing the shirt (front)

Testing the shirt (back)

Testing the shirt (back)

Once I got an idea, I continued latching the sleeves. At that point, I wanted to see what the whole thing looked like on me.

This is missing the hockey pants and shoulder pads to bulk up the suit. The pants should prevent the legs from caving in.

Test Run

Test Run

Last night, I started punching the hair into the face. I loop up a few strands of hair around the punching needle, a long steel needle with a barbed tip, and then punch it through the latex mask. The barbs hold on to the hair and push it through.

First Punch

First Punch

First Punch

First Punch

End of first night of punching

End of first night of punching

By the end of the night, my eyes were burning so much from starring at my monitor all day that I had to stop.

 

The work (wook?) progresses

Lots more work over the weekend. Before continuing this entry I just have to re-iterate how lucky I am to have @talzalina as my wife. This past weekend was our wedding anniversary and what did she want to do? She wanted to continue the work on the wookiees :)

All right

So doing some work on the pants at Luc’s this past weekend. I had to put the pants on to see where the grey would go… no, no one cut my legs :).

 

Shot Wookiee

Here’s with the shirt on… you can see the blending works.

Testing the blending of the shirt and pants

Then on Sunday, Ange gave up on the sleeves and went back to working on the back

Ange latching on our Anniversary

During this time I was working on the grey on the legs.

Adding grey

After an evening of more bad TV I finished the pants

Front of Pants

Back of Pants

Ange being silly

 

I’ve also picked up a skateboarding helmet that we’ll cut in half and attach to the skull. This will prevent the face from sliding like Luc experienced in his first Wookiee build. I also bought some hockey pants to fill in the legs a bit more.

Now excuse me while I go back to latching!

 

So much hair!

Well this weekend we started latching the hair. I remember when Luc had his first wookiee suit, each time we’d go over to his place I’d always come back with wookiee hair… well making a wookiee… now there’s hair EVERYWHERE!

To work with the hair, we’d first had to stretch it. We take it out of the pack, step on one side and then pull on it really hard as we use a hair dryer on hot over the hair.

Once that’s done, we’d cut it in 3. Then you rake it. We built these rake stations in order to get any knots out. The dogs found this part kinda funny.

The Rake

The Rake

Once ready, it’s latching time… of course, this was a group effort ๐Ÿ™‚

Latching

Latching Party

Luc teaching Ange

Luc teaching Ange

With the first day coming in close to 11 hours of latching. This is how far I got…

Chris' Day 1 progress

Chris’ Day 1 progress

And this was Ange’s progress

Ange's day 1 progress

Ange’s day 1 progress

Can’t say that’s too bad at all ๐Ÿ™‚ especially for first timers ๐Ÿ™‚

With an other few hours of latching on Sunday, I managed to do the full front side of on leg and half of the other side.

Weekend Progress

Weekend Progress

Now, by the end of the weekend, my arm was killing me. It’s surprises me every time how repetitive motions that you’re not used to can hurt so much after a while.

Now I’ll be continuing this every day until we’re done ๐Ÿ™‚

Wookiee Building is a Go

This has been something of a work in progress… we had started getting materials and working on the stilts slowly while waiting for our hair to arrive.

Now that we’ve officially started and the clock is on… here’s where we are.

 

Once we got home with the mesh, we got the girls cutting it to make the mesh shirts.

Girls working on the mesh

Girls working on the mesh

Luc then tried to get his head through the shirt as we were making it.

Luc trying on the shirt

Luc trying on the shirt

Sewing mesh is interesting. I managed to actually break a few needles… on mesh?!? Well the thread we were using was made for upholstery… it’s thicker and would snag and break.

Sewing

Sewing

In order to make the toes match up better and to give us more stability while walking on the stilts, we built some plywood bases.

You’ll also notice the aluminum L braces at the front of the stilts. These are part of a bigger system in order to prevent the legs from caving in.

Feet Work

Feet Work

Speaking of padding, we then added upholstery foam around the base of the stilts to fill them out. These will eventually be completely taped up and covered with a wookiee leg warmer ๐Ÿ™‚

Foot Padding

Foot Padding

Now that we knew the width of the foot, I got working on the mesh pants.

Are these pants to big?

Are these pants to big?

Test driving my new legs. I find it surprising how comfortable I actually am on the stilts. I would go running in them (yet) but walking around, standing still and even hunching down is pretty easy. Right now I need to practice turning as that’s the one area I’m having a bit of difficulty judging how wide the foot base is.

Testing out my new legs

Testing out my new legs