Angel of Death Costume

Hello and Happy Halloween!!

My name is Robert and I am from Chattanooga, TN. My customer I chose to make this year was the "Angel of Death" from Hellboy 2. This is the 4th year that I have made my own customer and every year I try and to find a new type of cosplay to make. This year I wanted to attempt to use EVA foam. I have seen different costumes use that material and found this costume would be a great start.

Once I decided what I wanted to I wanted to be the "Angel of Death" I googled images and got an idea of what I wanted to see. I knew I wanted the chest piece, mask, hands, and armor to be made of the foam so I did some searching online as what foam works best. I stumbled across EVA foam. This material was very inexpensive, you are able to buy rolls on Amazon.

The only materials you really need when using foam is a hot glue gun, box cutter, heat gun, and ruler.. I had watched some how to videos on youtube about using the foam and they are quite simple. The heat gun is a must because it allows you to bend the foam to the shape you need. The box cutter is a perfect for cutting the foam and the hot glue is perfect to seal them together.

The next step of my custom was assembling the wings. I had originally wanted to use a pneumatic system but after finding out it cost $100's of dollars i decided to go another route. I had seen a lot of videos on how to build different versions of wings and they all had very similar build.. But as luck would have it i was sitting in my house and happened to see my laundry stand and how it was designed and thought i could use that. So for $20 i went to walmart and picked up the stand and started putting it together.

My main goal was I wanted the wings to have movement So I thought of a pulley system that would allow me to move the wing s up and down. The biggest challenge of the wings were the feather placement. I needed to make sure that when my wings closed the feathers dint come off or to be bunched up to much. This was by far the most challenging part. I had read online that some people used close to 1000 feathers and couldn't really fathom that i would need that many. lol ohh was I wrong. after 3.. yes 3 separate amazon order of wings I was able to cover my 5 1/2 wing span. In total I used right at 800 feathers. I was able to apply the feathers to the wings since i had lined the wings with fabric that would allow me to glue the feathers on.

All in all my custom this year cost me right around $350 and I couldnt be happier with the outcome. The foam was a great thing to use and I am already looking to build a suit using just foam. I also added some teeth to the costume which I had found online that will mold to your teeth. It gave it that extra scary look.