Building the Star Wars Rancor Costume, Part 2

Previously, we showed you Frank’s 1/8th scale sculpture which was the basis for his Rancor costume. This week, we show you how that maquette is turned into a full-sized foam costume. Fabricator Ben Bayouth walks us through the foam suit build, including materials and techniques used to make the suit believable as a massive creature! (Thanks to Model-Space.com for sponsoring this project!)

Shot and edited by Norman Chan

Comments (10)

10 thoughts on “Building the Star Wars Rancor Costume, Part 2

  1. We tried really hard to get the wrist and neck to work, but we just didn’t have the time (built the whole thing in 3 1/2 weeks). I’d really need to build it all over again to make it work. call this Rancor v1.0 HAHAH

    the suit weighs very little, but even the super light weight arms, the leverage just makes it super heavy. i need to make a framework with springs/bungee cords to help alleviate the weight. Same thing for the head. Head was actually the heaviest single part. we’d need to reconfigure the mechanism, and reinforce the structure to hold it up. maybe next time!

  2.   are you working on a “framework with springs and bungee chords”? On the one hand it would be a great upgrade to get more life out Rancor suit. On the other hand, on to the next awesome project!

  3. These are great , more soon please! Don’t tease us. Frank – With the new Disney Star Wars lands coming I think Disney would be crazy if they didn’t order a few of these from your team.

  4. Glad to know that I’m not the only one that thought it could also go into a space suit form at this juncture. That would make for an interesting setup.

  5. This is quite a fascinating video. really has got my creative gears turning. I just have to figure out what I want to build in this similar process. Great video. Keep them coming.

  6. You guys should do more projects with Ben. He is very telegenic and expressive. And his enthusiasm and experience really comes through. Keep up the great work.

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