How do you make Samus Aran’s Varia suit from Metroid? If you’re Ainsley, also known as Pigtails and Power Tools Cosplay Creations, you do it with with a lot of hard work and Bondo. She spent 230 hours crafting the costume, she dropped over $500 on it, and the finished product weighs 45 pounds. Whew. The build started with pepakura files for chunks of the armor — it took over 200 sheets of paper to print the entire thing. In addition to fiberglass, she used Wonderflex for parts of the armor and EVA and craft foam for the arm cannon. All the different materials really came together for a uniform, polished look though.
See how the costume moves in this video:
Check out some build pictures below and see more on Facebook.