Building the Star Wars Rancor Costume, Part 1

At this year’s Comic-Con, we unveiled The Rancor Project: a huge foam-fabricated costume built by effects artist Frank Ippolito. The project was inspired by a test suit made by LucasFilm for Return of the Jedi, which never made it to the film. To show you how the Rancor was created, we visit Frank’s workshop and walk through the design process, starting with a maquette sculpture and patterning by foam fabricator Ben Bayouth. Using these techniques, you can build your own creature costume! (Thanks to Model-Space.com for sponsoring this project!)

Shot and edited by Norman Chan

Comments (21)

21 thoughts on “Building the Star Wars Rancor Costume, Part 1

  1. Videos like this are what make me happy to pay for the Tested premium membership. Awesome glimpses into whole industries I know nothing about. Interesting skills being explained and practiced.

  2. I am wondering. Is 1/8 scale standard for the effects industry? I’d have thought it would be 1/6 because that’s a common size for scale action figures.

  3. Great work, as always. But regarding the visibility and mobility of this suit, would it not be a lot easier to move around in it if you threw out the goggles, and mounted two small screens in the head, hook one up to the nose cam, and mount a downward facing cam in the Rancor’s chin? that way you can see in front of you and also watch your feet.

    I’ve spent some time in mascot suits and your feet are always a problem, even if you have a handler telling you where you should put your feet when encountering stairs and what not, it’s always a pain trying to figure out what they are actually trying to tell you, making you look like an idiot when trying to navigate a simple curb.

  4. Very cool to see how the patterning was handled. I also wasn’t aware Adam Beane sold those armatures! Definitely looks like it will be a fantastic addition for maquette sculpting.

  5. It’s so great to see how this got made. Can’t wait to see more of the foam fabrication. Also I’d like to learn more about Cx5, is Adam Beane showing up in later in the series?

  6. The 1/8 human figure, can it be used for pure poses for illustrations? or is it sculpt-able for the purposes of clay medium and a one time use?

  7. Sculpt-able. Check out Adam Beans site: http://www.adambeaneindustries.com/ Cx5 is a clay that is hard when cool and gets soft when warmed. I doubt it’s useful for an illustrator. That said, I bet it could work since it holds it’s pose once it cools. Check out a few of his Google hangouts on YouTube.

  8. I can’t stop staring at Zoidberg up there on the shelf. He looks so glorious with that luxurious mane.

  9. Bummer! Last time I wait to watch one of these. What if I want to watch “spam, scams, and commercially deceptive content.” youtube??

  10. It was all a deceptive scam???
    I’m crushed. I guess Frank didn’t really make a Rancor costume. It must have been a real Rancor faked to look like a costume.

  11. the video is back! thanks for being patient, guys, while i was on vacation. part 2 goes up this weekend!

Leave a Reply

Your email address will not be published.

One Day Builds

Adam Savage’s One Day Builds: Mercury Spacesuit Wr…

Adam is back to finish his replica wrist connectors for his …

Podcast - This Is Only a Test

Apple’s VR Conundrum – This is Only a Test 583 – 1…

We break down the confounding rumors about Apple's VR headset plans on this week's show, review the first two episodes of WandaVision, and share what we'd want out of a Willy Wonda prequel. Plus, the surprising things we learned from iFixit's AirPods Max teardown, and the return of a Moment of Science! SF Covid Vaccine notification site:…

One Day Builds

Adam Savage’s One Day Builds: Spacesuit Glove Wris…

Adam's latest machining project is a return to his Mercury s…

Making

Adam Savage’s Essential Modelmaking Cutting Tips

During his Jan 11th 2021 live stream, Adam gave an instructi…

Making

Adam Savage’s Favorite Tools: Blundstone Work Boot…

Over the course of filming Mythbusters and Tested, Adam has …

Making

Adam Savage Finally Fixes His Giant Swiss Army Kni…

In a previous One Day Build video in which Adam made a repla…

One Day Builds

Adam Savage Repairs His Ugg Boots!

It's the night before Christmas, and Adam sneaks away to the…

One Day Builds

Adam Savage’s One Day Builds: Knight Lighter!

Adam is well known for his love of armor, so he couldn't res…

Podcast - Adam Savage Project

All Good Things… – The Adam Savage Project – 1/15/…

Adam and Norm have an announcement to make--this will be the final episode of The Adam Savage Project. After 8 years of recording the podcast, we're refocusing our energies on other Tested projects including the bi-weekly livestreams. It's been a wonderful and amazing run--thanks so much for listening!

Tech

Tested: Elegoo Mars 2 Pro SLA 3D Printer Review!

We test and review the Elegoo Mars 2 Pro, a $300 mSLA 3D pri…