This costume was a very dedicated 6 month project. Using detailed character models and NECA's Anya Stroud action figure as reference, I created accurate and detailed pattern templates which I transferred on to EVA foam (commonly known as exercise mats). I molded the foam pieces using a heat gun, and carved textures out with a dremel. Each piece was coated in plasti-dip before spray painting and adding smaller acrylic details. The right arm guard, shoulder straps, and back "shell" have blue LEDs wired into them, all of which are powered by two 9 volt batteries - one for the back and shoulder connections, and one for the arm guard.
The LEDs actually proved to be a very difficult part of the costume to maintain. There were about 6 occasions where the wiring broke either at the base of the LEDs or the resister pieces -- right while I was wearing it at New York comic con (I actually had to to a quick wire surgery right on the showfloor with glue and aluminum foil!) After Halloween this year, I plan to completely re-do the shoulder straps, as well as the overall LED wire placement to ensure that it remains sturdy and safe to wear without worry.
For the under armor, I used a brown corset and light brown leggings with a "washed out" camo design. I was trying to replicate the worn spotted texture on Anya's pants, which worked better then I had expected. I carefully sewed the oval thigh panels on to the pants using a thin leather cord border around black laundry bag mesh.
Some other fun odds and ends that went into the costume were LOTS varied nuts bolts and screws, door hinges, rubber place mat material, thin sheet metal, and wire holders. And the Lancer of course, which is an accurate gears of war replica made by N.E.C.A. Aside from some of the mishaps with the LED functionality, I feel that this has been a huge success for my first armor build. I think this is my most impressive costume to date, and I am extremely proud of it!
**I also won NECA's 20120 Halloween costume contest, which really meant a lot to me considering what a huge role their Gears of war products had in making this costume possible!**
*1st place in Halloween massacre 8, 2012* ///
*"Sexiest" in 2012 N.E.C.A Halloween costume contest*