Muscle Suit Fabrication Part 2 - Cover, Sew & Hang Muscles

Ted Haines

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Learn how to fabricate a muscle suit with master creature effects fabricator, Ted Haines (From Dusk Till Dawn, The Muppets, The Bourne Legacy). 

In Part Two of his 3-Part course series, Haines teaches you how to build up your muscle suit with both firm and soft materials, including creating a rigid foam ribcage and realistic belly fat. From there he demonstrates his time-tested techniques for covering muscles with spandex and hanging them on a body form.

Whether you need to bulk up an actor to fill out a muscular superhero costume or add realistic "under the skin" muscle movement to your animal, monster or creature characters, this course series with one of Hollywood's fabrication experts will show you how to do it right.

Intermediate Level
3h 38m of duration
English (auto), Spanish (auto)
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Curriculum

      Materials

      CLICK on the links below to find the materials you need for this lesson. 

       

      Some items might be harder to find, but a little internet scouring usually finds you everything you'll need.

       

      Foam Mart

      McMaster Carr

      Reynolds Advanced Materials

      Smooth-On Inc.

       

      FOR YOUR WORK STATION

      Home Sewing Machine - Overlock or Zig Zag

      (This is not a must if you don’t have one, but it will make things easier)

      EPOXYS/GLUES

      3M 74 Spray or equivalent Spray Adhesive.

      Barge Contact Cement

      FABRICS

      1 Spandex Unitard - long sleeves and feet. We will go over making one as well.

      Spandex - 8 yards, yardage may very according to project

      Thick Muslin - 2 yards

      Elastic - 1” & 1 1/2”

      Heavy Hand Sewing Thread

      Webbing - 1” & 1 1/2”

      Heavy Duty Separating Zipper - 8” & 28”

      FOAMS

      Upholstery Foam - 2”- 4”

      Closed Cell Foam - L200 or interlocking kids play mats

      TOOLS

      Cutting Tools

      Razor Knife - snap of blade kind

      Personna Razor Blades - several boxes (20) blades

      Sewing Needles/Pins

      Hand Sewing Needles (curved or straight - personal preference)

      SUPPLIES

      Disposable Chip Brushes -  1”

      HEALTH/SAFETY PRECAUTIONS

      When working with toxic and/or dangerous materials or tools:

      ALWAYS read labels for appropriate use guidelines

      ALWAYS wear a high-grade respirator

      ALWAYS work in a well-ventilated area

      ALWAYS protect your skin

      ALWAYS wear eye protection

      Artist BiographyTed Haines

      Ted Haines is a foam fabricator. He's a wizard with scissors. We asked him to make something. He made a T Rex.
      See Full Bio

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