Here is a quick tutorial on how to make a batman costume. I made this for the Dark Knight Rises midnight premiere. The costume is finished and no WIP pictures were taken. But I will try to describe the process of making the pieces. I hope you all enjoy.
Step 1: Chest
The first piece of the suit that I made was the chest piece. I used an old Under Armour long-sleeve shirt as the base then used foam flooring and craft foam to build up the chest. I used the dark knight suit as a reference but added my own spin on the design. I spray painted the while thing in flat black(three coats, and then one gloss).The foam is attached to the Under Armour with lots of hot glue. After some trial and error I realized that the suit was too tight. So I cut a slit in the back of the shirt and added Velcro to secure the two sides together. Other pieces of Velcro were attached to the shoulders and elbows to connect other pieces of amor.
Step 2: Pants
The next part of the suit that I created was the pants. These were loose-fitting, stretchable, Under Armour Pants. The armor pieces were foam flooring pieces painted black and then hot glued onto the pants. I had to custom make the pieces of armor to fit my leg length and width. I used the Dark Knight suit as a reference. The chest piece shirt is tucked into the pants, and the armor is draped over the lip of the pants. The utility belt is used to hold the chest armor and pants in place.
Step 3: Cape
The Cape was the easiest piece to make. I used an old black tablecloth, cut scallops on the bottom, and then adjusted clip for around the neck.
Step 4: Cowl and Belt
The Cowl I bought online for about $25, the Belt was $8. They are both Dark Knight Rises Style. I altered the belt from Velcro to a clip for easier wearing and use.
Step 5: Gloves and Gauntlets
The Gloves are just mechanic's gloves that I bought for $8. The gauntlets were Made of craft foam, Velcro and Nylon webbing. The design of the gauntlets really depend on the look that you are going for.
Step 6: Shoulders
The shoulders were a unique challenge to design and build. They had to work on 3-axis and be thin and durable.I used the craft foam for the upper parts and the foam flooring for the bottom. I attached them to the shoulders on the chest with Velcro. There was also Nylon webbing added on the bottom to attach to the arms.
Step 7: Boots
These are boots I bought for $20 at Walmart they look really good with the rest of the suit.
Step 8: Full Suit Pictures
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Here a some final pictures of me in the full suit. Here is a link to a YouTube video of me in the suit at the midnight premier.
Step 9: Blueprints
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Here are templates for the suit I made. These are the ones i used to make multiple pieces for the legs, chest, and arms. I can't make a PDF file of the armor, but i will send scale pictures. Also I will attach the reference photos I used for the project.