How To Make Batman Beyond For Cosplay (Simple Steps!)

How To Make Batman Beyond For Cosplay

Are you a fan of Batman Beyond and cosplay? Do you want to play the second-generation caped crusader on the next event? Maybe you have seen exciting ads of the show on YouTube, or maybe you are addicted to the animation series. If you are looking for your next cosplay or costume party garb, then it’s high time that you wear the Batman of the Future costume on the street. Before slipping on the spandex though, you have to make sure that you get all the basics right, from the Batman cowl down to the cuffs.

So, what are the steps needed to become Terry McGinnis? Here are instructions required to help you customize your take on the character.

How To Make Batman Beyond Cosplay – Step By Step Guide

How To Make Batman Beyond Cosplay - Step By Step Guide

Step 1: Gather The Materials

Here is a list of items you need for the cosplay.

  • 5 to 6 tiles of EVA foam in black and red colors
  • Plasti-Dip spray or any multipurpose rubber coating of your choice
  • Black spray paints (with matte and glossy finishes)
  • Dremel tool
  • Sandpaper
  • Heat knife
  • Any glue of your choice
  • Non-adhesive Velcro strips
  • Small to medium-size clamps
  • Plastic resin
  • Concrete gloves in black
  • Headless black zentai or spandex suit
  • Red fabric for the cape
  • Boots

Remember, not every Batman costume is one and the same, so better get reference images of Terry McGinnis’ titular character. The costume Terry wore in the series has its own style yet it still retains the Bat-like characteristics that each iteration of the character possesses.

Step 2: Make Or Search For Suit Templates

The second step is to mind the template – cutting the EVA foam. If you are skilled with graphics software, you can make one using Adobe Illustrator. Use the reference images you have gathered to draw the template on top of the images.

The challenge will be making the cutouts for the arms, ribs and legs. If you have difficulty doing so, you can search online for templates. You can search for templates in URLS like Instructables or YouTube.

Next, cut out the paper patterns and check if the sizing fits your body precisely.

Step 3: Bring On The Foam Cutouts

You need the heat knife to create the craft foam cutouts for the armor.

The red EVA foam is meant for the Batman Beyond symbol while the rest is for the black bat armor. We use craft foam to provide bulk and heft to the suit. This will require a bit of elbow grease to properly fold and shape the foam into superhero muscles. Turn this into a cakewalk by using instructions from this tutorial.

Next, you have to work on the thigh and leg parts. As soon as you are finished with the cutouts, the design on the costume requires cutting into those very pieces. This is where the Dremel tool comes in handy – utilize its cutting wheel and cut around 1/8 inches in the craft foam. Remember though that this step needs to be accomplished prior to the shaping for a quality suit.

This process can be used on the cuff, rib and leg parts as well.

Step 4: Carving The EVA Foam

Step 4 Carving The EVA Foam

A proper shape is required to customize a Batman Beyond costume. For this step, you need the Dremel tool once more. Be careful with the tool though because it digs in the foam really quick.

Work on the oblique muscles by trimming on the foam’s back and front surfaces so it will fit your body correctly. The trimming will also prevent unnecessarily large grooves. Smooth down the bicep parts all over the edges as well to prevent said grooves.

For the neck piece, you can search YouTube and Instructables for the templates, or you can create your own using graphics software.

Step 5: Use A Coating Of Plasti-Dip

The Plasti-dip prevents the spray paint on the foam from cracking. Spray a solid coating of Plasti-Dup on the surface of the armor pieces for a quality suit. Allow to dry completely.

Step 6: Time To Heat-fit The Foam

Using the oven, heat it to 300 degrees then put the foam piece in it. Heat the item around 1 to 2 minutes max. Do not allow the heating to go on too long or the foam will shrivel and dry up.

The foam will become flexible once heated correctly. Hold the piece in the appropriate area – hold it up there for a minute max till the item has cooled down sufficiently to retain its shape. Use a heat gun to correct inaccuracies.

Step 7: The Painting Process

Spray the armor pieces with the black matte spray paint, around 3 coats for every piece.

Step 8: Work On The Zentai Suit

Step 8 Work On The Zentai Suit

This is one of the harder parts in making the costume since it will take you several hours to complete. Cut Velcro into strips that will fit every armor piece – two pieces per armor or more. Using sandpaper, buff the back of the foam piece where the Velcro will be pasted on. Wipe it clean then put glue on the foam and the Velcro strip. Allow to sit for up to 30 seconds then join the pieces together.

Clamp the foam and Velcro strip together and allow to settle. Once secured, draw using chalk on the Velcro’s back and position the armor in the proper spot while you are wearing the suit. This is to mark the area that the opposing Velcro piece will require sewing.

Work the armor pieces gradually, from the chest down to the ribs.

Step 9: Make The Cape

Take the red fabric and create ridges to make the cape. To better secure the cape on the suit, make foam caps and put Velcro on it as well.

Step 10: Work On The Gloves And Cuffs

Strengthen the foam spikes by applying 2 coats of liquid resin on them. Position them in place on the cuffs by hot-gluing the spikes. Using the glossy black spray paint, color the spikes and the cuffs.

Step 11: Create The Cowl

Step 11 Create The Cowl

For the cowl, you can get templates online – you can purchase a template or look for free ones. There are also YouTube instructions available for making the Batman Beyond helmet.

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Lisa Hayden-Matthews

An avid Skier, bike rider, triathlon enthusiast, amateurish beach volleyball player and nature lover who has never lost a dare! I manage the overall Editorial section for the magazine here and occasionally chip in with my own nature photographs, when required.
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