Kyle
When i was about 13 i wanted to go as Robin from batman. This was my first cosplay i suppose you can say because i wanted to make the costume myself. First i made the cape and that was also my first time sewing. I didnt want help from my mom so i decided to tackle the challenge myself. The first cape was crooked at the bottom. The second cape was way to small and didnt even fit around my head. The third cape was the closest to fitting so i went with it. Next i had to make the shirt and i was running on a goodwill budget. I got two shirts one was red and one was green for the sleeves. this was the worst one because there wasnt much i could do about it if i messed up (which i did). the shirts both fit fine until i cut them and sewed together. it was the most uncomfortable thing i have ever had to wear. The stiching was horrible and very scratchy and too tight and wasnt straight. Hahahahaha well im glad thats behind me. thanks for even reading this and making great props.
Jose
While working on my first cosplay i was worried about hot glue seeping out of the seems, so I used only a thin layer of hot glue on all my seems. And upon completion of the costume I took it to a local con on a hot summer day. I started posing for pics and for one lucky person immediately after posing my costume fell apart at the seems revealing my under suit (underwear) I went from iron man, to the flash in a second as I bolted to the parking lot. I have not returned to said con a few years.
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Kyle
I wantes to make a full latex black spiderman suit for a comic convention. I started planning and thought about moulding myself so it perfectly fit and then decided to buy a morph suit for a smooth mould. I proceeded to mould my legs,but every mould I made crumbled and failed.I thought I would have one last go moulding so took a mould of my head and then proceeded to sculpting the mask. When I moulded the sculpture, the mould again broke apart in the removal of the clay. On the day thw logos fell off the paint chipped and the zip popped off. I spebt 100 on this.
Kain
So the first time I made a helmet I thought I could harden it by applying wood glue to the inside. Not knowing that wood glue re-liquifies when introduced to water I thought it was a great idea. The day of the con came and I wore my helmet proudly, and like any cosplay it caused me to sweat. When the helmet was finally removed I had learned of my mistake because my entire head was coated in wood glue. I had to spend the rest of the con finding out ways to remove glue from hair.
William
My first ever cosplay involving foam was a couple of holsters I made for my steampunk nerd guns. About half way through the day they started falling apart ? that was before I knew about Bill and barge. Hopefully nothing like that will ever happen again!
Adam
I was making a mass effect suit and I had just got done with the chest and I left my HOT!! glue gun on and my suit and it cot fire when I was taking a break I went in to my dads shop and it did not smell good my chest was all brunt up good thing the floor was concert and nothing else cot fire I all never forget to unplug my glue gun the end.
Waylon
It was my first attempt at building anything out of foam,and I was starting out with a simple Halo magnum project. The disaster came as I made my second cut into the foam block and the utility knife (stanley knife) i was using simply started to tear the foam instead of make a clean cut through it. I tried a multitude of different ways to cut through varying from many shallower cuts gradually going deeper to just plain sawing at it!! regardless of what i tried the foam just wouldnt cut cleanly and i had to scrap the entire foam block i was working on.
Hank
So three Halloweens ago my girlfriend and I were helping our friends out with making various assorted costumes. Everything from a Nordic assassin, to Dr. Horrible, to Steampunk Batman, to Crocodile Dundee, to a Clockwork Girl, which turned into an awful mess of miscutting patterns, lots of misbent foam, and leather galore. The Batman costume ended up not seeing the light of day and the Dr. Horrible barely passed for a lab coat. A pair of wings were fashioned with hot glue for a Fluttershy and the Dundee himself even got a foam bowtie knife out of it. A faux leather foam shoulderpad was bent for the evening, despite it looking very much like foam, and a corset was too tight to wear the entire night. Overall, a lot of costumes passed muster, sort of, and fun was eventually had by most. Just after three weeks of scheduling hell and people promising to help.
J
Measured out the templates for an iron man shin with just enough room for my foot to fit through. Forgot to take into account the thickness of my foam and got my foot stuck. Had to redo part of it and added velcro.
Jose
Decided to give it a shot at making a Captain America helmet, using eva foam and hot glue. After all my hard work I finished, just needed paint. Painted it and figured it be ok to dry in garage. It was a hot week and when I finally checked on my helmet, you guessed it, a mess. The glue got hot enough to release all the seems and the rest is history. (More like the caps helmet was history) Lesson learned.
Brady
I made a bunch of pieces out of paper. They took me months to make so my little brothers and sisters decide to come in and crush all of it. Had to restart from the beginning.
Matthew
I was making a saw arm for my commandojack,from World of Warcraft, cosplay. I did my layers of mod podge and was beginning to use plastidip. I was taking my time with it and doing many layers but then my older brother though it would be fun to help. He did an extremely thick coat of the plastidip that forced me to peel it off after trying and restart from scratch. After all that when it was finally done my dog got into my room while I was at school and destroyed part of it. In the long run though when I put it back together it looked battle damage so I was happy with it.
Daniel
We were heading over to jpopcon in Copenhagen and my gf and I were going as a Jedi and Sith. Her Jedi outfit was largely soft so had a lot of tailored items with a bit of leathercraft for belts However, inspired by the SWTOR game I had gone to town on some Eva armour for my Sith and as we arrived at the event the nightmare of straps began to kick in as I had strapping popping. Worse still I had sensibly taken a cosplay repair kit with me but My glue gun has a UK plug on it and all the sockets were European. Were it not for some amazing European cosplayers helping me out my Sith outfit would have been a disaster. We cant get barge cement here in Sweden where I now live so would love to get barge to send some direct so we can experience this amazing cement that you speak so fondly of.
Robert
It was my second ever cosplay event soo as you can tell my costume wouldnt be the best but i had the best day until like half way through my prop axe got broken which wasnt that bad soo get the broken pieces in the car and went back then when posing for a photo with someone my armour had gotten snaged on the person belt and then rip one of the plates of armour had been ripped off soo i went to go put the armour piece in the car but on my way to the car my trousers also snagged on something still to this day i dont know what but it happened and when i heard that ripping sound and felt a cold breeze across my behind i had realised i had a gaping hole in my trousers soo had to leave the event early soo ye thats my disaster story.
Elliott
When I first started cosplay, I started like most other teenage kids, with Iron man mark 3. Low and behold I worked on this suit exactly 1 year and 1 day. By the time i was done I hated Fiberglass and pep. I thought this thing was perfect. I stayed home from school and finished it for the iron man 3 premiere. I had to work in the basement because we have a small house with no extra working space and my brother walked down without turning on the lights. CRACK! he stepped on the chest piece, unibeam and all. I walked down there 10 minutes later to find it almost in two pieces. I had to force a confession out of him because he wouldnt fess up. No Iron man premiere for me I guess.
Wesley
I was once making a hawkgirl helmet for a friend. I got everything together made the pattern of her head, cut my EVA, lined everything up and I went and tried to use regular old cyanoacrylate and it was such a huge mess! trying to hold the seems together while it bonded and it got all hot and just stuck to everything! I had originally planned to try barge cement for the first time but it hadnt arrived from Amazon and I had gotten impatient. So i had to do the whole thing over again but oh boy it was so much easier once I had the barge cement! great seems and all! I now use barge cement for most foam application or pretty much anything i need with enough surface area that i never want to come apart. I actually had a date recently and some of the upholstery in my car flared up an hour before I was to go pick them up, barge cement to the rescue!
Roberto
For 2011NYCC, the Mrs and I chose to attend as Poison Ivy and Two Face from the Batman series. Excited to be taking a girl and going in costume for the first time, I went all out on my cosplay. So, after 4 hours of applying makeup, followed by a 7 hour convention, I had the best time of my life and I looked GREAT! But what was the downside you may ask? Why was this such a disaster? About a third of the way into NYCC, my skin covered by makeup started to heat up. I had thought it was from having latex just sitting on it for so long. Another hour goes by and it got even hotter, and eventually, it just started to burn. So, the last few hours of the convention, I was literally cooking under my costume and having a severe allergic reaction to the latex, which I had no idea I was allergic to! So, for the next 4 weeks, I had a really bad burn/rash on the entire left side of my head and entire left arm. Apparently, I got really into copslay that year, or should I say it got into me!