Traje Benber

Bender
Here are some pictures of the Bender costume I made.  I made the costume initially because I was inspired by the large scale costumes I saw in the 2003 Comic-con masquerade.  I was able tofinish it in time to give him a test run at the Las Vegas Comic-Con on Halloween weekend. 
Unfortunately, I didn't know how it would turn out when I started, and I never took any pictures of theprogress. But here are some details on the construction of the costume:
I was originally going with the silver duct material (like on a dryer) for the arms and legs I even had it bought, but when I foundthis rubber stuff (quite on accident) I took all of the aluminum foil looking stuff back.
For the head I made 2 circles from sintra and made several vertical supports between them to make the basiccylinder shape and covered it with a skin of thin styrene. I then made another circle, cut it in half and notched the 2 haves together to form an X for the basic structure under the dome. Then aftersome styrene strips over the top, some fiberglass underneath, and lots and lots of Bondo for the gaps and seams I had the head and dome.
The eye socket is heat shaped sintra covered with a skin ofthin styrene. The eyeballs are 4" clear hemispheres from Micheals (fill it yourself Xmas ornaments) I painted them white, but finding the balance of enough paint to cover but not be too opaque was noteasy. This was my third attempt.
The antenna is a threaded rod covered with bondo and sanded to the final shape.
For the mouth shape I cut out the basic hole from the styrene skin and then made asintra framework covered with white fabric and black paint lines for the teeth that velcros in from the inside. This is where I will see out of the costume. I also cutout a portion of the lower jaw inthe center and re-glued together to form a slight overbite.
The cigar is a novelty cigar from the Halloween store with some hot glue for ash and an LED and switch inside. There is a magnet on one...