The hugely popular tabletop game Warhammer 40K is set in the far future and played with 28mm miniature figures. In preparation for Comic-Con, a few fanboys decided to supersize these little Space Marines and built 7-foot-tall, wearable replicas of their armor. Want to make your own? Go for it! It only takes 352 'terribly complicated' steps.

• Warhammer 40k Kits
• Warhammer 40k 3d Files Football

Warhammer 40k Kits

Step one: Join the 'Obscurus Crusade,' an entire forum devoted to creating costumes based on the game's Space Marines, Orks, and Tyranids. Or, for those not quite ready to enlist in the intergalactic army, creator Shawn Thorsson has provided an overview of his process at Instructables.

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Designing the Armor——————-

The first challenge in creating a life-size Space Marine is accounting for the difference in size. These iron giants are a couple feet taller than most normal people and that requires some design translation. People wearing the costumes have to walk on stilts and use arm extenders to make the proportions work and models need to be built around that.

Metal Armor, Made From Paper—————————-

Using a slick software package called Pepakura, cosplayers can pull 3-D data from videogames and turn those files into paper models. Once the paper is cut and folded, it is reinforced with fiberglass to give it strength for the next step.

Molten Plastic————–

With fiberglass models made, the space marine recruits can create multiple copies of the armor through a process called vacuum forming. Using this technique, a thin sheet of plastic is heated and pulled over a shape using a vacuum, leaving a near-perfect replica of the original.

Many Parts, Many Processes————————–

Not every part of the costume could be built the same way. The helmets were very complex and required the designers to use a casting process. Once the base models were completed, they were customized in the painting and decoration phase.

'I Love It When a Plan Comes Together'————————————–

After months of hard work the final costume started coming together. With a little paint and polish, these space marines looked ready to fight whatever baddies Emperor Zurg could throw at them. The costumes stole the show at Maker Faire 2012, and will likely wow even the most jaded Comic-Conner.

Honor and glory await any brave recruits willing to trudge through the 352 steps that take three-and-a-half months to complete. But be warned: This is not a project for the faint of heart. In order to enlist in the Space Marines you'll need to brave sharp blades, horrible heat, and noxious chemicals.

Or, you could just drop by San Diego's Comic-Con, marvel at the armor, then head over to the food truck corral.

Featured image courtesy: Instructables

• Great Bro...
  • Thanks. I'm trying to decide what model to do next. Is there anything you'd like to see?
  • Thanks. I'm trying to decide what model to do next. Is there anything you'd like to see?
    • Love this one Just about to buy it and I don't even collect Primaris! lol Fancy trying something Tau or Orky?Tau... Piranha, Broadside, KX139 (wow) or XV95 Ghostkeel would be totally epic!Orks.... Battlewagon, Big Mek in Mega Armour(no faces just helmets), Keep up the great work!
• appreciate eliminators/intercessors/inceptors/phobos armor/gravis armor. Would be a regular buyer in case of such supplies)
• You thinking about redoing the turret (I think thats it) for the new battle tank repulser?
• You thinking about redoing the turret (I think thats it) for the new battle tank repulser?
  • Yes I am going to get that done soon. Should be done by and of August. I'm just away for a few months so can't get it done sooner.