The Palace Guard in Gears of War is charged with protection of the Queen and, wait for it, her palace. Their armor looks intricate but also sturdy; it seems like it would be complex to build. RPF user SufferTheLocust accepted the challenge though and created a replica of the costume. He began with a leftover lower jaw piece from a Shao Kahn costume and got inspired from there. Here’s what he did for the head piece:
After re-drawing the shapes to be symmetrical i templated them on to a plastic sheet that i still don’t know the origin of. It’s between 4mm and 8mm, black, strong, reasonably light weight, can easily be cut with a knife and most importantly – thermoformable. It’s almost like a rigid plastic/foam. I was given it as a cover sheet for some cladding sheets we install in work and tried it out. It’s basically packaging to be discarded, most of the things i make includes this stuff.
He attached the heat molded foam attached to a cycling helmet base.
Read more at The RPF.