If you’re going to dress like an orc, you might as well build massive armor to fit an orc, right? Right. That’s what Steven K. Smith, also known as SKS Props, did. He built everything from scratch to ensure it would be on a properly massive scale. He made the armor from head to toe using EVA foam and crafted a giant muscle suit to go underneath the armor from upholstery foam and cloth. The muscle started with a shirt though. He says:
To start off I took an old long sleeve shirt and installed a zipper down the back for convenience. Then I plotted approx where the muscle groups would be on the duct tape dummy using craft foam. Because their arms are gargantuan to say the least I had to bulk up my arms and shoulders even before muscles were added. One and a half inch upholstery foam was attached to the chest arms and shoulders using 3m 74 spray adhesive. Once it had dried completely I went back in with Barge cement to make sure all of the edges were tacked down really good. I used a Dremel on the upholstery foam to smooth out the bulk. This step was extremely time consuming. I had to go very slow so that it didn’t tear the foam. This was also the start to a losing battle with static electricity, the damn foam stuck to everything.
You can see a couple WIP photos below and then you can read Steven’s complete build thread with tons more pics at The Replica Props Forum.