Build Log: Making Warhammer 40k Space Marine Armour

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As part of our maker series we will be bringing you some of the best builds from around the country. From Cosplay to Props to just plain cool we are going to be talking to makers about their latest projects to inspire you to take on that ambitious build of your own.

Our first build comes to us from Terry from BeCosplayFun with his first major Cosplay build.

So tell us a little more about your build, what is it? Why did you decide to build it?

The build is an Angels of Vengeance Space Marine for Warhammer 40k. I’ve always wanted to have my very own space marine suit and over the last few years have procrastinated, but after seeing some of the assorted cosplays at Supanova Brisbane 2017 I decided to take the plunge. I don’t play Warhammer though and so knew very little about the game or the lore attached to it so my learning curve was intense. Lots of youtubing, googling, joining appropriate facebook groups and befriending one or two other space marine builders helped out immensely to learn and understand enough to get the build done.

What is it made of?

The suit is primarily 10mm EVA45 foam purchased from P J Bowers on the Gold Coast QLD by the 2mx1m sheet. The structural support is 10mmx1mm aluminium strip and is minimal. The stilts are plasterers stilts (chosen for safety mostly). All skulls are 3D printed with a Prusa i3 Mk2 printer in ABS plastic. The foam is only heat sealed with a heat gun before painting.The base coat is Cabot’s self primed deck and exterior paint. Trim colours are acrylic and the suit is sealed with Rustoleum 2X satin clear coat.

How long did it take you to build? Can you tell us a little more about the build?

Initially 3 of us started this project with the intention of each building our own suits. Due to lack of time and funds for the other 2 guys I pretty much soloed the project with a lot of moral support from them and my wife as well.

I really didn’t have any clue where to start so I just began googling “space marine cosplay” to see if there were any plans available. There were some, but most were hard to follow. I got Pepakura (paper folding software) and some patterns and files from www.obscuruscrusade.com and some STL files from thingiverse, but mostly it has been scouring the internet for bits and pieces and assembling a hoard of info. I started the build on the 2nd of January 2018 officially, but didn’t pick up tools until about the 3rd week of January when I got the foam.

The second suit and the Sister of Battle took only 3 weeks because I had all the patterns, foam, tools, paint, prints, plans, etc. The Sister of Battle costume was by far harder as I only have a few internet pictures of someone wearing something similar to go on.

Was this your first build?

Yes… but in saying that, I have now built the second full space marine suit and a sister of battle costume (for my wife) in the last 3 weeks.

How much did this build set you back?

The total tally including tools (not the 3D printer though) was $1200.

Any protips you can share after making this or maybe stuff you learnt that you intend to use on another build?

A power file is your god weapon of choice when using EVA foam! But seriously, take your time with the research and watch lots of youtube videos on your chosen medium. Lastly, don’t be afraid to screw it up… you can always make it again.

If someone wants to find out more about your build or how to make their own where can they find out more?

Check out my facebook page “becosplayfun“. We are making a 3rd suit and going to be documenting the full build process in steps.


You can check out this awesome suit this weekend at Gold Coast Supanova and then again as part of the Starlight Foundation fundraiser in King George Square on May 4th with Cosplayers United.

If you are interested in finding out more or maybe building your own suit don’t forget to check the full album on the BeCosplayFun Facebook page and for more reference materials the Warhammer Obscurus Crusade forums.

Have your own build you want to get featured? Maybe you want to even be our maker correspondent? Drop us a mail via [email protected]