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Winter Soldier Cosplay

The making of my Winter Soldier cosplay! This was a fun one -- lots of challenges and new techniques for me! Watched a lot of videos to get some confidence and inspiration -- and to figure out where to begin the process. This one (https://youtu.be/hyHUMSdyd0o?si=ccMliTrMBhKgy79i) from Greg Enriquez had a fabulous template that I used as a starting point for the mask, tweaking here and there to include a few more screen-accurate details. This video (https://www.youtube.com/watch?v=ahKH1tMBOSE&t=336s) from Emily Boe and this video (https://www.youtube.com/watch?v=zsMWtlPYCo4&t=17s) from ANDCosplay were extremely influential in my process for tackling the arm. I'd been wanting to make this cosplay for over 10 years, and finally made high school me's dream a reality!
Mask made from embroidery leather, aida cloth, and EVA foam. Arm made from EVA foam, art thermoplastic, and late nights of contact cement destroying my sanity.

Had to do The Pose!

Had to do The Pose!

A quick proof-of-concept makeup test!

A quick proof-of-concept makeup test!

It's not a fun project unless your supplies are sprawled all over the table!

It's not a fun project unless your supplies are sprawled all over the table!

Front panel in-progress

Front panel in-progress

Front panel affixed to main mask

Front panel affixed to main mask

Spent quite some time staring at tiny details

Spent quite some time staring at tiny details

Progress!

Progress!

Close-up of the stitching details on both panels before they were glued to each side

Close-up of the stitching details on both panels before they were glued to each side

Finished!!

Finished!!

Duct tape and plastic wrap cast of my arm

Duct tape and plastic wrap cast of my arm

Tracing out the pattern pieces

Tracing out the pattern pieces

Pattern pieces cut out!

Pattern pieces cut out!

Pattern pieces transferred to a more permanent cardstock (you know, for all those times I'll be making my left arm again in the future), and traced out onto EVA foam

Pattern pieces transferred to a more permanent cardstock (you know, for all those times I'll be making my left arm again in the future), and traced out onto EVA foam

Mentally preparing myself to cut out all the foam pieces

Mentally preparing myself to cut out all the foam pieces

Arm!

Arm!

Making yet another duct tape and plastic wrap cast of my arm, this time detached from my body and serving a different purpose

Making yet another duct tape and plastic wrap cast of my arm, this time detached from my body and serving a different purpose

Arm plating details all cut out of second cast and ready to be traced onto more EVA foam

Arm plating details all cut out of second cast and ready to be traced onto more EVA foam

Figuring out the most economical layout

Figuring out the most economical layout

Attaching the pieces onto the forearm

Attaching the pieces onto the forearm

Pieces attached to the upper arm

Pieces attached to the upper arm

Like the caption says...

Like the caption says...

Sanding done after 5 layers of mod podge! Sprayed with two coats of a gloss black.

Sanding done after 5 layers of mod podge! Sprayed with two coats of a gloss black.

Testing out the fit of the silver sleeve I made (not my best work, but it gets the job done underneath the arm pieces!)

Testing out the fit of the silver sleeve I made (not my best work, but it gets the job done underneath the arm pieces!)

Sanding down the arm one last time (please let it be the last time....my real arm was in so much pain)

Sanding down the arm one last time (please let it be the last time....my real arm was in so much pain)

Like the caption says...

Like the caption says...

I was so nervous I'd get orange-peeling during this stage...terrified that I'd have to sand AGAIN.

I was so nervous I'd get orange-peeling during this stage...terrified that I'd have to sand AGAIN.

Absolutely THRILLED I wouldn't have to sand again and could finally call it a night!

Absolutely THRILLED I wouldn't have to sand again and could finally call it a night!

(Like I said)

(Like I said)

Still need to make a strap to keep the upper arm in place, but overall super proud of how this turned out!

Still need to make a strap to keep the upper arm in place, but overall super proud of how this turned out!

Took advantage of a gorgeous snowfall to do a little photoshoot!

Took advantage of a gorgeous snowfall to do a little photoshoot!

Accidental Hamlet pose

Accidental Hamlet pose