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Cosplayers: Arms, Armor and AwesomePhoto by: Brent Allen Thale

Cosplayers: Arms, Armor and Awesome
Photo by: Brent Allen Thale

Prop Build Photo Progression: Falcon Rocket Launcher - Overwatch

October 15, 2021

The following gallery is the photo progression (with annotations) of Pharah's Falcon Rocket Launcher from Overwatch. It's made almost completely from foam. I used EVA, XPS and Tooling foam. All of the parts are sealed/hardened in a hardshell resin coating from Smoothon called Epsilon. For more information about using Epsilon resin with foam please watch my video on YouTube.

Due to limited building time I did not paint this prop myself. This first photo (below) is the furtherest I completed the prop, which is final primer all ready for paint. I unfortunately have very few photos of the fully finished prop. The above photo is one of my favorites and believe it or not uses all natural lighting. Final paint was completed by Nimbus Cosplay.

View fullsize  Final prop in primer.
View fullsize  Main refrence image from Blizzard.
View fullsize  Secondary reference image by  Nick Russell .
View fullsize  Base tube from XPS Foam (pink) and heavy duty 4" cardboard tube. 
View fullsize  XPS foam. The brown filler is Elmer's Wood Filler.
View fullsize  Trigger guard piece hand shaped from XPS.
View fullsize  Outline of area for removal for rocket cartridge.
View fullsize  After material removed using a Dremel sandig bit for rocket cartridge.
View fullsize  Test fit of handle (XPS) trigger guard (orange tooling foam) and trigger shroud.
View fullsize  Block of EVA stacked together for the buttstock.
View fullsize  Buttstock after trimming and sanding.
View fullsize  Buttstock test fit.
View fullsize  Buttstock "nodes" added, more EVA foam. Compared to reference.
View fullsize  Test fit of Buttstock.
View fullsize  Circular piece that shrounds the buttstock patterend to tooling foam.
View fullsize  Circular shroud cut out.
View fullsize  Circular shroud shaped and detailing added with more tooling foam.
View fullsize  Adhering lower shroud.
View fullsize  Lower shroud (EVA foam) after being attached and flat area sanded with belt sander.
View fullsize  Overall test fit of each part.
View fullsize  Forward grip patterend onto EVA foam.
View fullsize  Forward grip ater being cut out with a scrollsaw.
View fullsize  Forward grip after being shaped with a sander and detailed edging attched. 
View fullsize  Forward grip fit test.
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Dafter Chief Part 1: Prep Stage →