A video posted by Jeremy Fisher (@0fish0) on Jun 27, 2016 at 11:59am PDT
Cosplayer and artist Jeremy Fisher, a.k.a. 0fish0, is becoming a rancor for San Diego Comic-Con this year. He started creating the massive creature from Jabba’s palace in Return of the Jedi in April 2015, and he’s nearing the finish line. Constructing the costume required building a frame from materials such as PVC pipes, a hula hoop, and bike brakes to control movement. Jeremy documented the project with notes during fabrication and said:
Made the mouth out of corrugated plastic and mdf. The jaw hinges in a similar fashion to a human jaw to add believable motion. The full head is hung from a PVC arm that connects to the backpack frame with bungee cords. This allows for the head to move around while supporting the weight. The head can easily be removed via the PVC arm as well.
As an animator on the stop-motion series Robot Chicken, Jeremy no doubt knows how to study the costume from a puppetry angle to make sure everything is just right for natural and easy movement. You can see that in the above video featuring a movement test.