hey Darryl how's it going man hey Adam
I'm doing well how about you it's really
nice to finally meet you at least via
via Skype yes sir thank you thank you
for um for this opportunity dude I love
watching the stuff that you make and you
are so prolific it makes me a little
tired just following your twitter feed
and I love that about you
and I'm also like I'm super psyched
about the Knights of Ren so let's talk
about where you've gotten so far and
where this where this project is sure um
so far what I've done I've modeled both
helmets for you and I um and I've
actually printed yours yours is already
finished do you want to see it yeah
totally want to see it so here it is Oh
Oh awesome
sorry printed so it is a lot of cleanup
work to do because of the orientation
that I've printed it in yeah but um for
this one I kind of wanted to highlight
two different kind of finishes for the
actual prints so this one would just be
like the regular bondo and sanding and
then for mines because the same more
smoother surface and there's not as many
details I was gonna go the X cc3d
route and then do the standing and the
finished norm on those and that is the
texture on this one similar to kylos and
that it's got that pebbled texture I
believe so from the reference pictures
they had drawn pictures but I would
assume they would be the same texture
yeah yeah I I think I agree with that
and then and I've got a bunch of I
haven't even started to delve in I built
two Kyllo costumes actually I built one
and then I got one from Innova so I have
one I can cut apart for the fabric
textures should I need it but there's
other parts to that costume right
correct um it looks like there's a
komodo that's underneath both you and I
hours and minds for the monk has a robe
Jon that covers his costume and then
yours has like a jacket that has looks
like there's a velcro strap and then it
comes
the torso of the body he also has arm
gauntlets right I modeled those I just
haven't printed it yet and then he has
some boot covers I'm similar to the
Captain America boot covers but they're
black and it looks like there's leather
strappings around the towards the upper
calf he also looks like he's holding a
light saber I can model that as well I
already did the belt buckle that he has
and I've made it to where we can just um
run a belt through through this through
the sides and then we could just have it
over the boat and then I also had a son
like insignia on it just to give it some
more life and then as far as I go
he has a chain and I already printed and
modeled that so it's really simple it's
nothing too out of the ordinary and it
just has some like Jedi some sick okay
guys thing on it you can see when it's
painted but right now you you can't
really make it out and then it has a
bunch of these around his calf on the on
the boots okay and then they both have
actual pouches on hanging off their
belts so I you know as far as the soft
fabrics I think I can do some research
over here to get to get some different
textures that we can sew stuff up I have
some kimonos here in my collection and
we can use those as patterns I also
actually happen to have a nice big Jedi
cloak and I've got like a screen
accurate kylo kylo hood so we can play
around with those once you get here to
get the fabric stuff Orkin and as far as
the lightsaber let me take a look at
that before you print the lightsabers
because maybe i've got some aluminum
stock here it might be fun to turn those
on the lathe and have them be really
dimensional that would be awesome you
know make them shiny and beautiful okay
I'm so psyched about this project man I
like I'm again actually I saw your spear
project before I got to see black
panther Wow really so I got to look at
your sneer smear was the only spoiler I
allowed myself before heading into the
theater
I actually just saw it Sunday dude it's
so moving so fucking incredible so is
that is that I think we're good for
right now I'll start to work on making
sure we have all the fabrics that we
need for your arrival we'll make the
decision about the light sabers via
email but you've got all the other stuff
on its way so I think we're ready for
you to come to the shop and us to get
building all right I'm excited dude I'm
so psyched all right man I'll see you in
San Francisco in a little bit thank you
sir bye Daryl bye hey guys it's Adam
from Testim and I'm alongside my new
friend & Co builder for this project
Daryl Bologna known online as the broken
nerd I've tweeted his stuff a whole
bunch of times
Daryl and I we're about to make a pair
of costumes yes sir there is actually an
end to this we are going to where we're
gonna be two of the Knights of Ren and
we are going to walk the floor at
Silicon Valley comic-con which is a
that's less than a week away so we are
we've got to construct these costumes
get them all ready get our characters
ready and hit the floor Comic Con in six
days so what are the characters were
we're making here we are doing the
Knights of Ren mm-hmm
so we are doing the monk and the rogue
and you're the monk on the rope yep yep
and I think the internet knows the rogue
as grenade face online and I noticed
he's got like different paint jobs going
on here some in this one some of these
are checkerboarded but in the film it
looks kind of more uniform correct I
believe in the film
it looks more like that chrome silver
color and I think they're just from the
concept art they had a different color
scheme going on so I'll take this in
same schedule you have already been
doing a lot of prep work for like a
month or so right yeah now walk me
through this is beautiful
how did you how did you go about making
that so I modeled this in arm cinema 4d
I just pulled in a 3d model that I had
that I used around my head and norm sent
me over your measurements so um I just
modeled around that and just scale it to
size printed this on my CR ten and I
usually printed in the on 180 on its
reverse access how come so this way it's
less clean up and then this way I don't
have to slice up the model right and the
bed is big enough where I don't have to
slice it up in and glue it back together
so you can print that as one whole piece
correct so these both have all these
almonds were printed in one piece and
they're printed in this access but the
only thing with that it leaves a lot of
cleanup to do on the top right so what I
did was I used bondo and I'm not really
a fan of bondo mm-hmm
but for in this case I did use it
because it helps with the cleanup
process on the top there was a lot of
cleanup in the in the front area here so
there was a lot of supports in this area
right when you see the time lapse you'll
see that there's just a ton of supports
around this dose and all those handed
down and for example this is what you're
talking about on these around these
vambrace is here I see these support
little nurnies in the turret so and that
gives and it sports come off pretty
easily okay and um they're pretty easy
to clean up but then it's just a post
work of sanding applying bondo spot
glazing putty sanding and then just
repeating that process of I know it well
it's amazing how lightweight these are
when you're all done yes
can I ask you if you did print it like
this is it the same in Reverse you have
less cleanup up here but more cleanup
down here there would be a ton of
support that to hold the whole thing up
and you escape all that out yeah so then
you're wasting time and filament at the
same time with with printing in in this
orientation so you saving time by
printing it this way and then although
the cleanup is more extensive on the
front end it's just worth it not to
print it this way yeah because you're
saving on filament what about people
with smaller printers where they've got
to slice it up do you have a preferred
orientation for that um whatever works
best and I think a lot of 3d prints are
guys they tend to Princeton an
orientation when they're not using a lot
of supports and then amazing a lot of
filament so if I was to slice this let's
say into four different parts I would
probably print it again this piece
sitting up
on this access mm-hmm and the supports
will not be as much because there's not
that overhang it wouldn't be as hard to
get the milk all right okay um and then
so for the middle piece I would print
that straight up and yes all right so we
and then here is the mug correct and
this is it's the same process but it's a
different color film correct okay
correct so this is printed in yellow
filament both of these were printed at
10 percent info so that is why it's such
lightweight I tend to print in a 100
percent infill sometimes because it's
more sturdy but these I just want to
save on time it didn't make sense to
print these in 100 percent infill
so 100 percent infill means that it's
completely solid correct okay correct
and it gives you just more of a solid
piece and um less likely to break if you
drop it right right right um yeah so
this was uh I think these both these
were like 80 hour prints a week and I'm
used to long prints so it was it wasn't
bad for me because I'm in and out the
house so yeah yeah but yeah these were
about 80 hours a piece I I mean you must
have had some prints where you print
something in 72 hours into an 80 hour
print something terrible goes on yes I
actually um I actually designed the
Hellboy sword yeah that you had me oh
yeah yeah and it was about 76 hours into
the print and um I believe it had about
10 hours left and came out totally
failed and it wasn't the principle was
anything that the printer did the role
of filament wrapped around itself so it
snapped
oh my god and it was about the nozzle
was about I couldn't say because the
nozzle was about this high off of the
actual print I thought it was printing
correct
so everything was working so I had to
stop everything and I was just like all
right I'll come I'll revisit this and
maybe another month or so is that what
you like and I've actually I printed the
Ben solo um light saber and we had a
snowstorm and I was about 15 hours into
it which wasn't long but power went out
had to stop old print so
it's it's a lot of trial and error in 3d
printing for now it is yes it's reducing
everyday okay so for for the robe we've
got the helmet and the two VAM braces
right and then it's my job on him to
assemble the other stuff I think I have
boots that work for this there also
looks like there might be some more
structural detail on the VAM braces well
we can add that oh I see you've got
these guys which are part of that ah I
see
okay there's things are interesting
because these were printed in steel
filament oh so when we stand these I
started standing a little piece here if
you look once you um go up to a higher
grit you start getting that a little bit
of a shine all that metal oh and that's
built into the filament correct so you
just stand this and we want too much
prep work so it looks kind of spotty
right now once we sand this down and get
it smooth and then just give it a Polish
you'll see that it brings out that metal
shine on these I had no idea people were
making filaments with that kind of esra
feature walk on exotic filaments out
there and then this is this is sort of
yours this is part of the necklace for
the monk okay so let's walk through the
classroom parts for the mark so the monk
has he has this necklace piece these
guests over here yeah cold and then this
is actually the belt buckle for your
cost okay so your belt will just slide
through that pull and then for the
monkey doesn't have a lot of pieces but
he has these individual parts that are
around hit the bottom with his boots
okay so I think there's about a six
along and then four on the bottom so
these would just get glutes alongside of
the boots now I could have sanded and um
maybe cast and mold these mm-hmm but I
just figured I'd just print a bunch of
them and then so we can likely we can
likely use pop rivets okay to have these
and that be nice and secure
I'm be curious to see how they how they
do when they go in so this is this is
10% in fullest varieties with 10% cool
so I go through the outside which is
what like sixteenth of an inch or
separate and then on the inside it's
like a matrix yes these were printed and
not like a honeycomb um in fill pattern
okay and then what else so now then
there's all the fabric parts of these
two costs
yes so you've got this long robe which
is fascinating because it goes like
right from here all the way down correct
and then it kind of like gets longer as
it hits the bottom of it out that's a
ton of awesome fabric that's gonna be
really cold and also looks like there's
two different kind of um pattern or two
different kind of fabrics this looks
like a light of color oh right and then
there's like this rug over that yeah
that is a separate color and then
there's this whole sort of almost kendo
wrap around his chest all right which
looks like it goes I don't know if
that's a skirt or just pants I think
it's pants there's actually another
reference picture that I have and it
looks like he's just pants okay don't
worry so there's a lot of moving parts
it is now Tuesday we've got until Friday
I think we can get it done I totally get
it I actually bought some mannequins for
this oh wow we can put them up and start
to dress them and pattern off of them
okay I I think that it's probably best
if you start working on the hard parts
while I start getting the fabric and
fabric amounts ready you know for my
first kylo Ren costume I just used a
pair of black Dickies as the pants
because you've never seen them kind of
back there and they just it's a good
hearty fabric that just kind of
disappears okay I know it's like the
Cape will pretty much cover the pants
those exactly the most part I think I
might have a pair of boots that would
fit you okay so you want to start
working on the the accessories and the
the attachments here and I'll start
gathering the fabrics together would
love to I tweeted recently that all
mannequins kind of suck and it's really
true it's really hard to dress costumes
on mannequins but I have discovered for
my uses in this shop three-quarter
mannequins are the most ideal they allow
the pants to hang they're easy and quick
to dress because you don't have to
thread on to pants
yeah and they break down faster I mean
sorry
it's easier to take a costume off the
mannequin faster I don't mean that they
break down although they can break down
the weak point of these guys is often
right here where the tightener attaches
to the main pole but like I said it's
always a balance with the mannequins all
right yeah that's good all right Daryl
I've got this extra I have like so many
different vinyl boots from Amazon I
think these will fit you okay and those
would be pretty good for attaching these
guys sure so why don't you get started
on that and then when you get these
plates to a place where it's time to
attach them I'll reveal some of my
attachment method cool all right yep all
right so what I'm gonna do is I'm gonna
start removing some of these support
materials in here and they usually pop
out pretty quickly but because it's such
a tight spot I'm gonna use this needle
file just kind of going in take some of
this support material out
a usual process for sanding on parts
like these and any 3d printed pieces I
usually start off with a higher grit so
100 is usually where I start at and then
I move up to 150 and then 220 and then
at that point I will be at a stage where
I can go ahead and hit it with some
primer and then I'll come back and get
some of those problem areas and then
start the sanding process all over again
and then get it to a point where it's
kind of smooth like where these helmets
are at so standing against the print
lines so the print lines are going in
this direction so I'm sanding against
that direction all right dude and back
from the fabric store cool I have some
options so in looking at luck these
different textures I trust some textures
that contrasted nicely in the same way
that kylos do although I found a wall
for the inner tunic Wow okay that looks
nice yeah it's got a nice different
texture to it and then I thought of this
kind of shiny twill for the inside for
this inside thing okay what do you call
that the hood and then look at this that
is nice this is kind of like this great
it looks almost wet but it definitely
has a feel of kylos kind of waxed fabric
thing Wow was the perfect you like it
yes okay I'm gonna get on patterning
how to sew these two costumes up because
there's a lot of a lot of yardage but I
notice in looking at monks internal rap
is that there's almost like a kendo feel
so I've actually pulled out my kendo
armor that I have from the Mythbusters
episode where Jamie and I were smacking
each other in the head and I thought I'd
just take a look at some of that and see
if there's anything I can learn from the
pattern to kind of make work for this
because it's about the same sort of deal
right like it's like that kind of thing
so I could follow that with a vest yeah
that's actually kind of great awesome
okay so I feel like I can pattern off of
this baby
okay then the question is a nice thing
about this ah I wish I could remember
the name of this garment I know it has a
name and I apologize for not knowing it
off the top of my head but the nice
thing about it is it lays flat I am
looking at one whole panel here and that
makes it a quite a reasonable thing to
to be able to cut out if it seems to
those of you who are genuine seamstress
and seamstresses and that I'm being a
little cavalier with the patterning on
this I am because the the the
undergarment that I'm working from is an
extra-large so I feel like I've got a
lot of room for making it smaller I'm
just trying to get close here and I'll
be able to actually mock this up and put
it on Daryl before I start to sew it
again
I feel like I've got a lot of room to
move here
so what I think I'm gonna do on this oh
yeah look at that I can pull these way
into here and then yeah and then what
I'm gonna do for the arms is likely make
them taper down cool right with little
velcro here so they have that feel and
they might be a different fabric than oh
no they'll be they'll be this fabric but
it'll take four down to the glove cool
yeah and then the back is the same yeah
I feel like actually let me just make
one mark here come on
so I just pause because I have a fabric
here that has one texture on one side
and a different texture on the other
side and I'm about to cut apart two
pieces with chirality that means they're
mirror images of each other
and if I didn't get the fabric fullness
correct I would cut out one with a
texture on the outside and the other was
a texture on the inside and that would
be bad and I know that's bad because
I've done it many many times
I know I know I'm using white thread on
black costume but that's cool because
this is all the inside you won't ever
see it Killa
it's not pretty but it'll do I will be
honest with you I am good at building
stuff and I'm good at thinking about
shapes in my head but when it comes to
how a sleeve connects to the body of a
shirt I am mystified by how that works I
mean I understand intellectually and
from an engineering standpoint what's
supposed to happen but every time I've
done it man it is a hornet's nest of
complication
all right hey Darryl yes sir then try
something on you here all right so yeah
that's gonna be a tight fit around you
here you go this is the inner inner
tunic it's gonna come around like that
and I'm gonna give you a yeah and I'm
gonna give you a like a border up around
here okay this feels great
yeah I like the way it comes into the
arms yes that's nice with the gloves
that'll be cool we can we can do a
little pin there too okay great I love
it awesome whoo all right it's taken
progress
skip your shot
Oh
I'm feeling good
that's feeling pretty cool I got you
some of the kylo Ren fabric from my old
Cairo red costume as that cool as the
border here Wow on two screens oh it's
all gonna get weathered okay
see there's two belts that's a belt belt
which means that yeah which means that
we want to figure out where this lands
on you and I'll sew this seam so you
have a belt buckle for your pants you
can put on your pants but then there's
this secondary rap here and that is
something that I can I can come up with
another way to do that okay actually you
know some it's it's it's it's something
like that you know you around there and
I can make it velcro around to itself
all right
that's great I dig that cool how much
fabric do I buy I'm I too much fabric
that's how much I look for so this is
just a sample of an old kylo / tunic I
had and I think it needs to go a little
lower but I think it's the right shape
Yeah right like draped over this and
I'll figure out a way to make the hood
part of this yep
Wow it's sort of shaping up yes
all right Darryl
I'm going to measure your shoulder to
the break see here if you would hold
that right there
we're gonna go down to yeah I'd say I'm
gonna go to 54 inches and we can trim it
up okay perfect
woohoo I have made the monks inner tunic
and his belt and I've mocked up a twill
hood it's a cacophony of black texture
fabric because that is what kylo Ren is
so I'm assuming that's what all the
Knights of Ren are so I've got the hood
the inner tunic the belt and now I'm
working on this outer tunic for which
I'm actually copying kylo ren's one of
kylo ren's tunics I feel like having a
lot of cross-pollination between the
parts makes sense to me and I've just
measured Darrell's shoulder - how far
down I want this to go and it's 54
inches so yeah we're actually pretty
good here it's it's shaping up nicely
I'm actually feeling pretty good about
it I'm you know there's a lot of
finishing work to do but
Oh what are these what are these these
are the new savage industry tape
measures you can buy these at Adam
Savage calm here's what we're gonna make
a difference between Kyle Lohse costume
and this one we're gonna flare it more a
lot more so I'm gonna come out like that
because I think it should drape down
yeah that's cool I'm into that and again
if that doesn't work I can just trim it
back no cost for the attempt if you have
fabric with a texture on one side and a
different texture on the other side and
the one of those two sides is the
texture you want when you fold it up
fold it so the texture you like is on
the outside then you don't lose it as I
have done many times yes Oh hide your
fabrics light under a bushel
all right Darryl yes let's try in a
couple things let's put this on there
you go yeah okay so that's gonna come
across like that and that hold that
there I'm just gonna get a safety pin
then go ahead hand behind you yep it's
working it's great the mannequins a
little broader than you so it's actually
fitting nicely okay so what seven so if
I bring this forward like the dude dude
it's happening that's really nifty so if
I bring that in like this and these guys
if that literally just almost sews there
like that that's kind of what I want you
can I'll have to add a piece to that so
it goes all the way down okay and we're
getting some full-face balaclavas you're
like Slenderman whatever they call them
but and we'll put it we'll put armature
wire in here so we can sculpt that okay
and we'll also once we're finally
fitting it will probably have velcro in
it over your helmet and have obviously
you'll have foam in your helmet yep cool
I think we're making progress
yes all right here let's stick your you
can take your helmet off and you can
move yes good very freely fabulous
Ceylan once I sand this down there's
gonna be a lot of deep lines that no
matter how many sanding I do it's not
gonna blend in properly
so once I've sand this down I'm gonna
use the spot blazing putty to getting in
in between those deep lines and then
blend everything together so we have a
smooth surface and this came from
support material and from the raft in
the orientation that I printed it in so
I printed it this way and then we have
some support material right here so when
I remove it kind of left that rough
surface on the bottom here
great in a t-shirt that's fine awesome
on an industrial machine the raising and
lowering of the foot is done with your
knee and it was just this little lever
here but when you're on an industrial
big machine you can do all that foot
raising and lowering with your knee and
it's really nice and fast I've long
thought about adding that to this
machine but clearly I have not gotten
around to it yet
I'm not adding a wire to the edge of the
cowl to facilitate getting it to sit
nicely this is definitely a thing I've
learned by reading about other
cosplayers wonderful tips and tricks
because it's hard to get callus to sit
right and actually kylos kylo ren's Cal
has a has a bit of an armature in it
I'm wrapping up today Darrell I I have a
belt for you so I'm gonna work on your
belt buckle okay
I've ordered this the the under tuning
opens low enough that I've ordered you a
turtleneck shirt cool so I think that'll
do nicely to hide everything going up
and we don't need necessarily a whole
bunch extra detail here but we'll see
okay and these guys just I think
tomorrow morning we'll start attaching
these to the boot yep and I'm just gonna
hit this with primer these are great and
then should be ready to go tomorrow
Jedi Kirk I mean what is that said sif
characters I can't believe the
resolution you can get and that was
actually printed at point to lay all
right
that's amazing yes all right
see you tomorrow morning all right thank
you sir
