Movie Replica Costume

This unique character was brought to life with a ‘real’ world approach. In other
words, just how would a man burned alive and subsequently sent to hell look if he
were sent back to our world as an avenger of evil?

Spawn or HellSpawn…Born from ashes and condemned to roam our world as
disfigured unlikely hero.
Our replica started with a throw away test
suit used for the motion picture. The test suit
or pre-suit was similar in design but nothing
like what ultimately made it to the big
screen. This pre-suit was first and foremost
all smooth. No burnt skin texture or charred
skin detail what so ever. Secondly, the
muscle structure that was sculpted for this
version was different then what was finally
used on screen. The stomach and
abdominal area was completely different as
was the rib cage, groin area and arms. In
the simplest of terms, it was a totally
different costume. The beauty of this
however was that it was still sculpted onto
Michael Jai White’s life cast so in that
respect we had a perfect body structure
to work off of.
Once the suit was pieced together we began the sculpture work and transformation
from what was meant to be a comic book inspired suit to a replica of the movie
used Spawn suit. This is the process of the underlying charred tissue. The actual
skin would then be sculpted overtop at a later phase.
           
If you zoom into the images of the pre-suit
you’ll notice all the tear marks and seams.
All this was pieced together meticulously to
bring it back to as much of it’s original self
as possible.

The most noticeable difference was the
crotch skull and the ‘V’ detail that starts up at
the chest area and comes to a close at the
crotch skull. Clearly in this first stage it was
meant to be more comic book influenced.
Time for a new crotch skull.
The top picture is from the pre suit.
The right picture is our new skull based
on the movie design.
This test casting of the skull was painted chrome
and weathered accordingly. We then proceeded
with a new casting which was unpainted and fixed
to the entire work in progress costume that when
complete, and new full body molds would be taken, this
detail would blend in seamlessly.

Cowl sculpture in water clay.
Two days to complete from start to finish.

 

 
Both hands and forearms sculpted from
scratch and detailed with the same charred
flesh look as the rest of the body. Designed to
blend in and look as a one piece costume.
This is what the raw latex urethane
foam casting looks like before all
the paint and finishing work is done.
And here was our reference.
Compare and judge for yourself the
amount of work that went into
the restoration and final
transformation of this costume.
Chest skulls to complete the look. These
were cast up separately and added to the
final wearable cast suit.

The burnt face appliance seen here is an
original casting from the films production
studio that was not used during filming. It is
not our rendition but rather an original.