Dark Knight Rises at the 5 Drive-In!

"Don't you wanna know who he was?"

"I know exactly who he was... he was the Batman." — John Blake and Jim Gordon

5 Drive-In at Oakville

The Dark Knight Rises at the 5 Drive-In! The epic conclusion of the Nolan Dark Knight franchise shines in spectactular blockbuster glory.

Dark Knight Rises

The expectations were set unrealistically high both by Nolan's amazing cinematography and by the fans, and the gates were flooded with movie-goers for the event way before doors opened.

The evening was filled with the buzz and excitement of the fans, the flurry of the staff and artist panel, the anticipation of the raffle and prizes, and of course, the Dark Knight himself.

Suiting up in front of the Batmobile

This entire past month of preparation finally came together in the one event, and I must say that I am truly impressed by it all.  The set up crew got there around 6pm, and from there it was touch and go.

Everything came together as quickly and seamlessly as possible, the Drive-In staff were extremely helpful and accomodating for all of us, and everybody pitched in to make it all happen.

Even had me some face-time with Batman Glen from Orangeville, not to mention his gear (*silly grin*).

Adonis and Brittany

Caroline, Jill, and Adonis

The artists panel featured some amazing talent, headlining Adonis Howard, Brittany Marr, Caroline Austin Smith, Jill Dhakura, amongst others, all drawing free sketches after free sketches for Batman fans and movie-goers alike until the cows came home.

I have to give it up for these guys, because after the sun came down, and while everybody else were enjoying the movie, they were still drawing like nobody's business.

Batman Glen and fans

And Batman Glen.  Wow, I can't see any kid to have ever met this guy and then grow up to not like Batman.  What a public face and personality.  Kids were climbing up all over the Batmobile, and the guy just grinned and beared it.  He even gave me a couple of pointers as to building the suit and the batmobile during a short break.


Fans pay tribute to Batman and Batgirl

But of course we can't forget the fans.  The turn out for the event was absolutely amazing.  People were lining up to get pictures with Batman and the Batmobile, to get free sketches from the artists, and all in all the fans made such a wonderful day of it all, it was really incredible.

Movie-goers crowd the event

We did some special things for the fans as a special thank-you.  On top of the free sketches that were given away, seven prizes were raffled off at the event, including graphic novels and a Batman card game (courtesy of Todd from Image Collections), as well as an Arkham Asylum styled batarang.

Aside from a few minor hiccups here and there, all in all the event was, in my opinion, a huge success.  The whole cast and crew worked seamlessly to bring the whole thing together, the staff at the 5 were awesome, and the fans made us feel like it was all worth it in the end.

Adonis and Batman Glen

5 Owner Brian and Adonis

5 Manager Mike and Adonis

Don draws for 5 Drive-In staff

R I S E

Dark Knight Rises... And Shines!

"We were in this together, and then you were gone. Now this evil... rises. The Batman has to come back."
"What if he doesn't exist any more?"
"He must... he must..." – Jim Gordon and Bruce Wayne

Some days, it seems like the work of a masked vigilante leading a double life just doesn't seem to end.  While multiple things have been happening in the workshop lately, suturing the mask, doctoring tools and holsters for the utility belt, my "other mask" (that of Bruce Wayne) has been busy.

Wayne and the Batsuit

What possibly can a billionaire-playboy not push off to his butler/employees?  Well, a promise made and an opportunity of a lifetime.  Through a group of my good friends, specifically my comic book artist friend Adonis Howard and comic book store owner Todd Mara, I've come to be involved in a promotional crew for the new Dark Knight Rises movie (in theatres today!)

The 5 Drive-In at Oakville invited us to make a big event of this Saturday's showing of the Dark Knight Rises, the third and last installment of Christopher Nolan's epic Batman trilogy.  So for the past month or so we've been rather busy creating signs, banners, and artwork, and pulling the whole thing together.

Bruce Wayne dances with Selina Kyle

For our work we've been rewarded with admission to the advanced screening of this spectacular show last night, before the rest of North America even gets a chance to see the opening title.  Something that others would spend anywhere between $70-$150 per seat for in theatres.

But all the money in the world couldn't have prepared me for this.  This magnificient end to the Batman legend shines through all those that came before it, leaving all of us gripping at the edge of our seats right from the very beginning, all the way past the very end.  Every angle, every movement, every detail was true to the iconic mood and theme of the Dark Knight.

Catwoman, defiant

The care in putting detail into plot development is unbelievable.  What's more, as the plot develops, those of the audience who are initiated into the plot of the past two movies slowly come to realize, that Nolan's quite carefully and quite deliberately weaved these two prequel blockbusters in a way that seems like he was planning and building up to this climactic finale all along.

Now, I will admit, that I'm a sucker for certain parts, and I really do wish there was a bit more focus on Bruce Wayne (Batman), and on Selina Kyle (Catwoman).  But with this many layers to unfold in so short a time, and so many things to blow up...  Nolan quite successfully floored even a lifetime Batman fanatic like me.

In the grime and the wreckage of Gotham city under siege, the Dark Knight truly shines.

I can't wait until we all get to see it again on Saturday.

An Airdrop

"It's a problem with the graphite, sir. The next 10,000 will be up to specifications."
"At least they gave us a discount."
"Quite. In the, uh, meantime, Sir, may I suggest you try to avoid landing on your head?" – Alfred Pennyworth and Bruce Wayne

While work is ongoing to help bring the armor templating back on course, a care package came through across the border via a friend's planned visit, on relatively short notice, which deserves a rather gigantic personal thank you.



Adult Batman Full Mask



Even through a bout of baggage loss and holds, my friends find a way to pull through, which is absolutely amazing.

So for your visual pleasure, I present to you the Adult Batman Full Mask, Adult Batman Utility Belt, and the River Road Pecos Mesh Gloves.

For being the most expensive item on this particular trip, I'm thoroughly disappointed with the Adult Batman Full Mask.  While I completely understand that this is supposed to be a one-size-fit-all kind of item, and that I was probably going to have to make do with some foam lining on the inside, there were a number of manufacturer's imperfections on the item, the least of which being frequent bumps, scuffs and discoloration on the mask's exterior, no doubt due to a bad molding or mold release.

Aside from that, the nose sockets were uneven AND misaligned, and the eye sockets have imperfections in the edges.

A rip above the closure

The worst was the velcro on the back.  Not only did the terrible sewing job start to tear as soon as I tried to undo the velcro to inspect the closure, there was a gigantic dollop of a bump right at the top of the closure, which led the back of the mask to rip as soon as I tried it on for fitting.  Huge disappointment.

And this is supposed to be an officially licensed product.  For $34.99, us amateurs could've done better.  DC, it's time to stop outsourcing your manufacturing to China.  That said, I'm hoping with some work I could still recover this mask and be able to get some amount of use out of it.

River Road Pecos Mesh Gloves

On the bright side of course, the other two items were absolutely spectacular.  The River Road Pecos Mesh Gloves were exactly how I imagined for them to be, and because of the good tailoring, I am almost afraid of ruining it by adding any more features to them.

If I do, it'll be only to add some knuckle guards, and maybe a little bit of resistive thread on the fingertips for the touch phones.

I really can't say enough about these gloves.  They're comfortable, they're an absolute perfect fit (Thanks to the amazing online help at Motorcycle Superstore), not to mention the quality is just superb.  Very cool.

Adult Batman Utility Belt

Last but not least, the Adult Batman Utility Belt.  Overall, no complaints about the item.  The quality of the item is good, and it is exactly as ordered.  Plastic, which is a bit of a shame, as it will probably see less years than it should, but then again, the detail on this thing is just gorgeous.

While I'm probably going to do some work on this item, namely replace the velcro closure at the back with a plastic buckle, and add a foam and velcro lining in the front to accomodate an inner belt, I'm glad this item came as ordered, and will accomodate various standard-sized holsters with little difficulty.

Bat-Gadgets: The Batarang

"He's only one man!"

"The most... uh... dangerous man on Earth..." – Protex and Superman, JLA Issue #4

Unrefutability one of Batman's most dangerous tools in his arsenal, the batarang (originally spelled baterang) is a roughly bat-shaped, semi-lethal throwing weapon.  Earlier versions were indeed styled after boomerangs, whereas later adaptations of the batarang have become more of a shuriken-like weapon.



Batarang (Arkham Asylum/Arkham City Style)



Whatever its shape and format, the batarang has always been one of the most versatile and useful tools in Batman's armaments, used to disarm and disable assailants, cut various objects, carry small charges of explosives or electicity, or double as an impromptu grappling hook.



Although seldom referred to by name, the batarang is undoubtably one of the most iconic symbols within Batman's posession, not to mention that it's an all-time fan favorite.

It goes without saying then that Batman would most likely have one or several of these within his crime-fighting tools all the time.


I took it upon myself to create some of these, following an instructable, and with sound advice from a machinist and an airbrush artist.

Batarang - Folded

The result:  Foldable batarangs.



Now, while these particular batarangs are styled after the Arkham Asylam and Arkham City video games, after learning the skills necessary to machine these, I've found it's not necessarily at all difficult to create batarangs with any other style or focus, simply by varying the techniques and materials a little bit.

For example, the Nolan films foldable batarang can be easily made using plexiglass and a small mortise hinge, whereas this particular style shown requires a furniture nut, a flathead screw, and a pair of magnet tabs.  How you style them is simply a matter of cutting the shape of the weapon on plexiglass.



Batarang - Back View



But it seems one thing is for certain.  People LOVE batarangs.  Fans, and even friends that do not necessarily love Batman much have started asking me to sell these.  We'll see.

Does it come in black?

There's never been a huge amount of talk about Batman's boots.  Yet another little-attended part of the costume, Batman's boots has always been regarded as simply a part, or an extension of the suit itself.

Batman's Boots are essential to crime-fighting

That having been said, Batman's boots are an essential part of his crime-fighting outfit.  As the caped crusader swings through Gotham's treacherous terrain, dodging gunfire, knife cuts and various types of assault, the boots must be durable and comfortable.  Not to mention that the recent animated and Nolan film incarnations have begun to add various hidden gadgets inside and as part of the boots themselves.

This had me thinking quite a long time about the boots.  The original intent was to have a durable, stylish pair of boots that would fit both the bill and the budget.

Unfortunately, the process for tracking down the RedHead Front Zip 10" Waterproof Lined Rubber Boots had been notoriously difficult.  In fact, it was excrutiating to the point of absolute ridicule.

As an internet marketer myself, I must say that Bass Pro Shops has majorly failed in delivering in customer experience, satisfaction, and product availability.  The boots currently appear as a clearance item online, but every size is out of stock online, and the product is indicated to be available in stores only.

So I decided to visit my only local Bass Pro Shop to find the product.  After searching through the footwear section, and consulting two associates and a customer service representative, I was told that not only does the Vaughan Canada store not stock the product in question, but that they simply do not follow their own corporate website at all.

My friend in Mesa Arizona had pretty much a similar experience at his local store, finding nothing in either the footwear nor clearance sections, and was told that the product was not in stock when he called a day later.

Edit (18-Jun):  From an online support ticket...

Response (Debbie)06/15/2012 06:39 AM
Derek,
Thank you for contacting basspro.com. Your business is truly appreciated.I am sorry, however, this boot has been discontinued and is no longer available.
Best regards,
Debbie
Bass Pro Shops
2500 E Kearney
Springfield, MO 65898
1-800-BASS-PRO

All that trouble for one simple, lousy pair of rubber boots.



Bat Boots... Begins

After a few more searches and generally disappointing results, I ran into some dumb luck.  A local shoe store was holding a closing sale, and they carried a 10" nondiscript pair of black leather boots, allegedly made by a local footwear company.

I ended up bagging these at 50% off for $45 + tax, which is a little bit more than the cost of the RedHeads, but the fact that they are genuine leather, is more than worth that price.  It will probably need some kind of sleeve to extend the length of the boot, but they will do nicely I think.

Bat-Gadgets: The Bat-Phone

"It's the Bat-Phone." – Alfred Pennyworth

Although probably not one of the more exciting Bat-Gadgets of all time, the Bat-Phone has always been an essential tool in Batman's arsenal, helping to relay critical information to Batman and his aides in a timely manner for the purposes of crimefighting.

The Bat-Phone has evolved much over the decades, starting from the big red pulse-dial clunker in 1966, to the more recent incarnations of a high-tech mobile cellular device in the Nolan films, capable of performing many cool detective tricks like sonar imaging and all kinds of smart phone stuff.

Be it as it may, the TV and film incarnations of the Bat-Phone have always seemed to focus on the tactile, handheld device.  With technology the way it is these days, you'd think that Batman would simply hide a bluetooth earpiece inside his headset, and set a speed dial on his oh-so-trusty iPh... erm...  I mean Bat-Phone, so that he could call Alfred when he's in serious trouble.

Plantronics Explorer 210 Bluetooth Headset

Which, is why I've secured myself a new Plantronics Explorer 210 Bluetooth headset, to hide under the cowl.  A very ridgid body with a slim profile, comfortable in-ear speaker with a contoured ear-tip delivers decent enough sound (you have to turn it all the way up if there's a lot of road noise, but otherwise it's fine on medium), and I'd say decent battery life (8 hours talk time, 8 days standby), all packaged in only 11.5 grams of weight.

Cool part is, it only cost me $21.99, and I earned $0.44 maCashback for getting it through SHOP.COM.  Hey Nolan, time to get Christian Bale one of these, don't you think?

Portability

"... And men fear most what they cannot see." – Ra's Al Ghul

 A few more weeks of templating, acquiring materials and planning had me suddenly thinking.  In the 1990's incarnations of Batman movies and animated series, Bruce Wayne had made it possible to pack up his entire batsuit inside a suitcase, that could easily be transported in the trunk of one of his luxury vehicles, or delivered to him by Alfred, enabling the Caped Crusader to be able to "suit up" on the fly, in the comfort of his rear seat.  This function of portability seems to have been lost in the recent Christopher Nolan films, with the more rigid and bulky looking batsuits.

That being said, there was probably more than one reason that Wayne wanted to have the batsuit redesigned with more modularization between Batman Begins and Dark Knight.  On film, his primary reason was that he required more range of movement with his suit.  However, modularization also comes with the double edged sword of being easier to pack for carrying, weighed with its increased exposure to weapons penetration.

This had me thinking about portability and response time issues.  How realisitically can a Dark Knight styled batsuit be packed into a suitcase without possibly damaging the suit's features, and how easily can a suit be donned?  Typical response time for a typical metropolitan emergency department is around 5 minutes.  Can Batman make it to the scene of the crime before the police do reliably?

In the effort of exploring these ideas, I had dug out a rather old carrying case for an antiquated casette camcorder.  First impression is that this case should be about the same size of a regular carry-on suitcase, and should be the kind of size that the batsuit would have to fit into, given the requirements for both portability and anonymity.  It wouldn't do to lug around a few luggages the size of bodybags every time you're near the scene of a crime.

The great part of this is... This carrying case is actually quite durable.  In fact, I think it's made of some kind of polyurethane or hard plastic.  They don't make stuff to last like they used to, that's for sure.  The question now remains...  Will the suit fit?

An old VHSc Carrying Case

Interior with foam inserts removed

Range of Motion

One of the major issues I've been contemplating was the matter of having semi-rigid armor and still being able to provide range of motion.  After comparing the several different designs between the Batman Begins, Dark Knight and Dark Knight Rises film costumes, and finally decided to go with the Dark Knight / Dark Knight Rises design.  While it does not offer neck protection as high up as the Batman Begins batsuit, and probably leaves a larger throat area open, it seems to offer a good range of motion if propped out properly.

The neck ringscales should ideally be held together with some kind of semi-flexible backing, and I realize that foam would not be the ideal medium for this, since with sustained extreme flexure, foam is likely to tear.  I'm currently contemplating a rubber material to be used for this section, and possibly for some other sections of flexible assembly backing.

I've seen a tutorial out there that uses bicycle inner tires for the entire kit and kaboodle, so I might go that route, if no other economical options present themselves.  That said, here's the neck template pieces and paper fitting.

Neck Paper Template

Neck Ringscales Fit

Edit: After much deliberation, I've decided to separate the neck piece at the collar from the rest of the suit, and velcro it onto the compression suit during "suit-up".  This decision was made to ensure that there is a good, tight fit and such that I can easily fit my head through the suit's collar.

Prototyping Begins

Whether it is your first or your nth DIY, it is important to know exactly what you're doing before cutting into your material, in case later you should come across an "oops".  For me, this is especially important, as not only is it my first time even creating a foamcraft costume piece, I also have very little to go by in the ways of detailed blueprints and other such good things, other than some fairly decent templates and instructibles on various websites and forums.

So, that said, the first step of course then is to create a prototype, using an easily workable and fairly inexpensive material: paper.  While paper is not great for bending complex curves and simultaneous 2-axes deformation, it is a great place to start, so you can get an idea what some pieces should look like.

I've decided that my first paper template should be a fairly easy piece of the armor, the bracers.  So without further adieu, here's the result of the papercraft today.

Gauntlet Paper Template

The Spike Assembly

Front View - Right Gauntlet

Left Gauntlet Fit

Left Gauntlet Inside View

Left Gauntlet Spike Detail

Foamies Templated

A Question of Reliability, Answered

Reliability and durability is an issue that I've grappled with for years, even before taking on this project. Coming from an engineering background means that sometimes you tend to overthink certain things in a design process. The common train of thought is that even if you cannot make something to be perfect, the goal should be in getting it to the point where it is close enough, that it is virtually unrecognizeable from being so.

So naturally, the question of "how well can this suit take a hit?" entered my brain as soon as I set down to the planning process.  Multiple things (like protective gear for hockey and soccer, metal plating, and flexi glass for example) have been sourced out and compared initially in a physical thought experiment.

While all of those might be great things to use and try, pre-made sports protective gear doesn't offer the customization that I wanted, and working with rigid stamped/casted sheet material is just too cumbersome and time consuming.

Enter James Bruton from xRobots.co.uk.  I accidentally came across this gentleman's video on plastic casting a foam item.  Lights went off and I said, "This is perfect!"  I can shape the foam easily to create the armor pieces I want, and then cast each piece in plastic, and voila!  I have plastic armor, without having to worry about the possibility of someone punching ol' bats in the chest and denting the foam.

After watching his video tutorial, I decided to contact James, and he was kind enough to give me some tips on how to make the whole process work within the specifications of my project.  That was very awesome of him to do, so here I would like to share his video for all of you as well.

The keen-eyed will notice that in the previous post, I've already included the Smooth-Cast 65D Roto Liquid Plastic Compound in the shopping list, which is actually a semi-rigid polyurethane plastic.  Perhaps in the future I will experiment with a rigid plastic compound also.