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.

Elegoo Mars 3 4K Resin Printer Review!

Making

Elegoo Mars 3 4K Resin Printer Review!

This week in 3D printing, we review the Elegoo Mars 3, a $30…

Podcast - This Is Only a Test

Visions – This is Only a Test 618 – 9/24/21

Norm and Kishore check in to talk about the success of the Inspiration 4 mission, the just-announced Mario movie, and what surprised us most about the Star Wars Visions series. Plus, Microsoft's revamped hardware lineup, new iPhone reviews, and the future of wireless charging.

A Tour of Grant Imahara’s Shop

Show And Tell

A Tour of Grant Imahara’s Shop

Friend and colleague Fon Davis gives Adam Savage a tour of G…

Adam’s One Day Builds: Hasbro Mandalorian Helmet Repaint!

One Day Builds

Adam’s One Day Builds: Hasbro Mandalorian Helmet R…

Adam shows you how to take Hasbro's The Black Series Mandalo…

Adam’s Favorite Tools: Heat Gun and Iron!

Making

Adam’s Favorite Tools: Heat Gun and Iron!

Inspired by one of his favorite YouTube channels (Ted Woodfo…

The Mystery of This Original Rocketeer Stunt Pack

Show And Tell

The Mystery of This Original Rocketeer Stunt Pack

Adam visits Prop Store to take a look at an original stunt p…

Portable Fog Machines for Propmaking and Photography!

Show And Tell

Portable Fog Machines for Propmaking and Photograp…

Want to add fog or fake smoke to your projects? We round up …

Podcast - This Is Only a Test

Apple’s Diminishing Returns – This is Only a Test …

Another duocast this week, as Jeremy joins Norm to recap the announcements and disappointments from Apple's California Streaming event, including the new technolgoy in the latest generation of iPhones and Apple Watch. Plus, more thoughts on The Matrix, the launch of the Inspiration 4 mission, and the first trailer for Marvel's Hawkeye sho…

Adam Savage Tours Ghostbusters: Afterlife’s Farmhouse Set!

Culture

Adam Savage Tours Ghostbusters: Afterlife’s Farmho…

While on location of the Ghostbusters: Afterlife set, Adam S…

Adam Savage: How I Wear My Face Mask

Show And Tell

Adam Savage: How I Wear My Face Mask

With masks being part of our lives for the foreseeable futur…