Johnny of Junkers Cosplay was commissioned to create a Reckless Fist costume from Elsword for a booth at Anime Expo. The character’s armor contains several different shapes so Johnny started out by making armor patterns with card stock. It’s always a good idea to start with an inexpensive material like cardstock or craft foam. When he was happy with how it looked, he cut the pieces out of plastic and used a heat gun to form the plastic and add curves. He did the same with the armor pieces on the shoes and used E6000 to glue the plastic armor right to the boot.
One challenge of making the costume is the giant 5’5″ sword. It was the first time Johnny made something on that scale. He made the base with composite board and used expanding foam to add support for the plastic plates that he added to the sword in various places. Again, he used a heat gun to bend the plastic into place and secured it with Liquid Nails. He had to tape off every section one by one for painting.