Process

Warsong commander: Shield making of

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In addition to the complete costume’s making of, as well as the one about the axe, here is the making of the Warsong Commander’s shield.

Patterns

For the axe, I first re-drew the shield in vector graphics on Illustrator while placing each part of the shield on separate layers. This shield is a bit huge, so we had to plan different assembly parts.

Warsong Commander Shield
Re-drawn model

Warsong Commander by Wei Wang
Warsong Commander original artwork by Wei Wang

We started by printing the different parts of the shield…

Cutting and taping
Cutting and taping

Paper shield
Paper shield

Foam basis

…To transfer them onto EVA foam. From these, we obtain the shield basis.

Transfering patterns on the foam
Transfering patterns on the foam

Foam basis
Our foam basis

We also cut the borders, that we glued using neoprene. Then, Joris carved them with our Dremel to get the right shape.

Gluing borders with neoprene
Gluing borders with neoprene

Shield + borders
Shield + borders

Carving foam Dremel
Carving with the Dremel

Beveled borders
Beveled borders

Central logo carving
Central logo carving

Worbla

The most difficult part here was to not be able to apply a single sheet of Worbla over the shield pieces (they are too huge). We had to make the fittings as clean as possible so that we couldn’t see them on the final result.

Worbla : fittings
Worbla : fittings

Worbla borders
The Worbla borders

Sanding Worbla
Sanding Worbla

foam worbla
Worbla cover
Logo fittings

shield worbla

Plywood

A complete wooden shield would have been too heavy, however we wanted a real wooden texture so Joris cut a 12mm-plywood that we glued on the foam basis.

Plywood shield
Plywood

Plywood

Emblems

1. Sculpture

I sculpted my emblems with Plastiline, using my vectorial drawing and other World of Warcraft references as models.

Working on Plastiline
Working on Plastiline

Plastiline emblems
Plastiline emblems

2. Resin casting

We made silicone molds out of my Plastiline sculptures. Maël then made an aluminum cold cast and glued them on the plywood using neoprene.

Note: aluminum powder allows, when sanded with steel wool, to get a metallic aspect.

Cold casting in a silicone mold
Cold casting in a silicone mold

Cold casts
Cold casts

sanding dust
Because I’m haaaappy ♫

Assembly

Shield is assembled with reinforcing bars on the back. We placed fixations so that our screws stay hidden behind the spikes and the central logo. Lastly, the central logo is fixed with Velcro strips.

warsong shield assembly
38 pieces… Let the puzzle begin!

shield back
shield screw

spike shield

screw shield
spikes shield
shield screw
shield screw
shield emblems
velcro wood
velcro foam
velcro worbla

warsong commander shield

Final result

Warsong Commander Cosplay
Warsong Commander cosplay
Hearthstone Cosplay
World of Warcraft Cosplay

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marie@blackowlstudio.com

Marie Katzenmayer, 25 ans, est illustratrice freelance. Passionnée de game design, de musique métal et fan de Tim Burton, ses spécialités sont le Pepakura, la sculpture et la peinture.

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