I get a fair number of questions about this between here and Deviant Art, so here’s a post that will hopefully answer a number of them! :)
My Rex cosplay is a combination of things… Some that I bought and left unaltered because they were close enough to what was needed already, such as the amber lens goggles and black boots, and others that I purchased and made alterations to as necessary. (EDIT: Forgot to mention, the goggles are Vega I-Gear goggles. Have been asked before what kind they are.)
The t-shirt is actually two shirts - white and teal of the same size - that I bought and cut in half horizontally, then sewed together. The teal gloves and red track jacket I ordered online. (The jacket came from spreadshirt.com for anyone wondering, the gloves from welovecolors.com.) I also got the yellow-orange nylon online that I used to make the glove cuffs (as the gloves themselves are normally just one solid color). The jacket was altered using a couple of plain orange t-shirts I got at a hobby store and cut up. I couldn’t find jersey style material in that color that I liked for the jacket striping, cuffs, etc. so that was my solution to the problem. Everything on the jacket was either sewn by hand into place or fixed down with a fabric glue called Liquid Stitch. That same orange t-shirt fabric was also used to make the two rectangles on the Rex shirt. The back of the jacket (with the metallic silver gear and wording of “Start A Revolution”) was a custom design I specificed to be added when I made the online order. The pants are a store bought pair of black mens jeans, the designs hand painted on with light blue fabric paint. It took two coats to get it that solid and bright, the process made easier by creating templates from thick card stock and tracing them onto the black fabric with a white fabic pencil. The dogtags are something extra I added, much like the design on the back of the jacket. I wanted to make my cosplay unique and the tags were something I wore every day months ahead of the convention I was going to as a reminder to adhere to near daily work outs and healthier eating habits so that I’d be in better shape for the cosplay. Even now, the tags don’t leave me. I wear them when I work, sleep and even shower. They’re stainless steel, so they don’t rust.
There are a few things about the costume that aren’t perfect and that I’m not entirely happy with, but Rex is only the second character I’ve ever cosplayed, so I’m still learning and have settled with what I managed to do this time around.
The BFS is something I’m still working on. Unfortunately, due to an unexpected family medical emergency that came up prior to the convention last September, I lost a lot of time to work and only the Rex costume itself saw completion by November. The BFS is being constructed out of a combination of PVC pipe, insulation foam, wood glue, hot glue, paper mache and styrofoam. Two different grades of sandpaper, a break-away-blade box cutter, paint brushes, a pipe cutter and a few other tools are aiding me on the project. The blade by itself is four feet flong and detaches from the hilt and handle, which are an additonal two feet in length. If you look closely at the image in the upper right hand corner of the montage photo, you can see the hole I’ve cut in the side of the sword base so that I can reach through and grip the PVC pipe that runs down the middle. Once the BFS is closer to completion, I’ll be buying some metallic silver fabric to sew into a sleeve that can be pulled over my lower right arm to help with the illusion that my arm is actually part of the weapon. Hopefully I can get back to working on this in another two or so months when the weather here in the US midwest warms up more.
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