The ZYGON Build Diary Part 2
Hey Gang
So Paul and I were back at it on Day 2 of the Zygon Build. Today was all about getting the body sprayglued onto the form, starting the hands and feet plus refining the head shape and chest curves.
More Zygon goodness and Info
We started by added several choice pictures and screengrabs to help guide us through the process.
Revised Reference Material
Then we got a hard hat cheap at Home Depot to build the head on so it would rest comfortably.
Hard Hat
I'd bought a new kind of spray glue called 633 Foam lock that still gave texture but worked super well locking foam and fabric together. This stuff was the bomb and super cheap at Ronco Upholstery.
Spray glue
Using the Spray Glue the foam of the body was attached to the shirt/body form.
Then Paul figue dout on the fly the extra chest pieces needed to beef up the area and ive it that outward curve.
Barging the chest peieces
The foam now glued onto the body form.
To give it something to balence on scraps of firmer L-200 foam were used on the front and back to give the structure of the curve on which we'd add the mattress foam with barge.
Making the Curve from L200
Once determined the band saw was used to cut out the chest piece with the right bevel cuts.
Cutting out the chest piece
Barging up the chest peice
It was a lot of foam so the barge process was a bit tedious bit worth it.
Front Curve
Back Curve
We eyeballed the rightrange of curve from the reference pictures and especially comparing it to the curve of the action figure.
Cut Chest Peice
Head Shape
Cutting interior peices with the help of a laser guide on the band saw
We went back to the head when the base of the body was done. First thing was to create rings or attachments of foam inside to hold it to the helmet which we placed backward son the head as the lip would have gotten in the way on the front.
Backwards helmet
Interior head.
Tools of the trade.
my Head cast ready to be used to help us on head fitting.
So we belt sanded the helmet to rough up the surface and give the glue something to grip to. We jury rigged foam sections in two layers to hold the helmet in place.
Sanding down the helmet to give it a nice surface to barge to.
Barging the helmet into the Zygon head.
Checking out the new head on the form and my head cast.
Once in place it gave us a good start for the fit on body placement and how to best revise the shape to make it look more.... well Zygon like. Primarily a bit was shaved off the front outward curve, the sides were shaved off and replaced with new inward curving piece to create the inward taper and finally the giant puffy unibrow was added in two piece wit bare to really take home the basic Zygon head shape. To refine it further proved challenging so we went back to spray gluing the legs for the time being and getting calves and thighs on the form.
Spray gluing the Calves onto the body form.
Work in progress.
Tools of the trade.
The process was repeate don the thighs.
Spray gluing the thighs on.
Because these were based on the Morbius patterns we had to cut down the amount of bulk on the calves, thighs and so on to give it the Tapered Zygon look, often checking the fit and then cutting down the foam as need be so when spray glued it fit more snugly.
Paul then barged on a zipper on the back for closure using some spare leather and a fairly large plastic zipper.
Seeing the whole costume coming together
The original Shoes I bought at Target before they are Zygon-ized.
We used a pair of Van like slip ons- ideal for this- no laces to get in the way and made from suede to help with a good texture for glueing.
Test fitting the torso and head!
We took a pause for me to test fit the torso and head and we were feeling happy about the shapes and I have to say it was pretty comfy!
Finishing the foam on the arms
Finally the 1/8" foam was added to the lower arms to finish them off as the Zygons didn't have much for muscle below the elbow.
Adding Cups to the end of the arms to gve it form so the final 1/8 foam could be spray glued to the shirt.
Mostly final head shape.
Feeling good about the body and head we moved back to hands and feet where Paul worked out an odd pattern to create thehude 3 toes on the feet which we folded up from matterss foam, barged on one at a time.
Suction cups fingertips in progres
Adding Foam Toes to the Shoes.
While Paul worked out the toes on the feet, I worke don the hands, curling stripe dof 1/8" foam and curling them into rings or fruit loops I then spray glued onto each digit to create the end suction cups on the hands. Then the back was given the 1/8" foam treatment to bulk them up slightly.
Curling 1/8" foam and spray gluing on for the end suction cups.
Covering the back of the hand with 1/8" foam for "skin"
Stopping point for Day 2
With a lot accomplished we wrapped for the day!
I'll return soon with more on the build in Part III
-Honorarydoctor
So Paul and I were back at it on Day 2 of the Zygon Build. Today was all about getting the body sprayglued onto the form, starting the hands and feet plus refining the head shape and chest curves.
More Zygon goodness and Info
We started by added several choice pictures and screengrabs to help guide us through the process.
Revised Reference Material
Then we got a hard hat cheap at Home Depot to build the head on so it would rest comfortably.
Hard Hat
I'd bought a new kind of spray glue called 633 Foam lock that still gave texture but worked super well locking foam and fabric together. This stuff was the bomb and super cheap at Ronco Upholstery.
Spray glue
Using the Spray Glue the foam of the body was attached to the shirt/body form.
Then Paul figue dout on the fly the extra chest pieces needed to beef up the area and ive it that outward curve.
Barging the chest peieces
The foam now glued onto the body form.
To give it something to balence on scraps of firmer L-200 foam were used on the front and back to give the structure of the curve on which we'd add the mattress foam with barge.
Making the Curve from L200
Once determined the band saw was used to cut out the chest piece with the right bevel cuts.
Cutting out the chest piece
Barging up the chest peice
It was a lot of foam so the barge process was a bit tedious bit worth it.
Front Curve
Back Curve
We eyeballed the rightrange of curve from the reference pictures and especially comparing it to the curve of the action figure.
Cut Chest Peice
Head Shape
Cutting interior peices with the help of a laser guide on the band saw
We went back to the head when the base of the body was done. First thing was to create rings or attachments of foam inside to hold it to the helmet which we placed backward son the head as the lip would have gotten in the way on the front.
Backwards helmet
Interior head.
Tools of the trade.
my Head cast ready to be used to help us on head fitting.
So we belt sanded the helmet to rough up the surface and give the glue something to grip to. We jury rigged foam sections in two layers to hold the helmet in place.
Sanding down the helmet to give it a nice surface to barge to.
Barging the helmet into the Zygon head.
Checking out the new head on the form and my head cast.
Once in place it gave us a good start for the fit on body placement and how to best revise the shape to make it look more.... well Zygon like. Primarily a bit was shaved off the front outward curve, the sides were shaved off and replaced with new inward curving piece to create the inward taper and finally the giant puffy unibrow was added in two piece wit bare to really take home the basic Zygon head shape. To refine it further proved challenging so we went back to spray gluing the legs for the time being and getting calves and thighs on the form.
Spray gluing the Calves onto the body form.
Work in progress.
Tools of the trade.
The process was repeate don the thighs.
Spray gluing the thighs on.
Because these were based on the Morbius patterns we had to cut down the amount of bulk on the calves, thighs and so on to give it the Tapered Zygon look, often checking the fit and then cutting down the foam as need be so when spray glued it fit more snugly.
Paul then barged on a zipper on the back for closure using some spare leather and a fairly large plastic zipper.
Seeing the whole costume coming together
The original Shoes I bought at Target before they are Zygon-ized.
We used a pair of Van like slip ons- ideal for this- no laces to get in the way and made from suede to help with a good texture for glueing.
Test fitting the torso and head!
We took a pause for me to test fit the torso and head and we were feeling happy about the shapes and I have to say it was pretty comfy!
Finishing the foam on the arms
Finally the 1/8" foam was added to the lower arms to finish them off as the Zygons didn't have much for muscle below the elbow.
Adding Cups to the end of the arms to gve it form so the final 1/8 foam could be spray glued to the shirt.
Mostly final head shape.
Feeling good about the body and head we moved back to hands and feet where Paul worked out an odd pattern to create thehude 3 toes on the feet which we folded up from matterss foam, barged on one at a time.
Suction cups fingertips in progres
Adding Foam Toes to the Shoes.
While Paul worked out the toes on the feet, I worke don the hands, curling stripe dof 1/8" foam and curling them into rings or fruit loops I then spray glued onto each digit to create the end suction cups on the hands. Then the back was given the 1/8" foam treatment to bulk them up slightly.
Curling 1/8" foam and spray gluing on for the end suction cups.
Covering the back of the hand with 1/8" foam for "skin"
Stopping point for Day 2
With a lot accomplished we wrapped for the day!
I'll return soon with more on the build in Part III
-Honorarydoctor