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TF2 Demo vest blueprints by greenzaku TF2 Demo vest blueprints by greenzaku
Feel free to download and use :)

I used about a square metre worth of thick, black, closed cell foam rubber from Clark's Rubber in Australia to make the vest itself, and a thin strip of foam rubber to make the side straps. The pouches are just boxes wrapped in duct tape. This was a rushed job so no time to make nice pouches!

I re-used the pouch from the sniper cosplay here: [link]

Other materials:

Contact adhesive (CHECK the description to see if it works on rubber! Some types will corrode rubber)

Box-cutter (the sharper the better. Even so, foam rubber will pucket easily...I just lived with it)

Six drink cans (Get big cans if you are a big person and small cans if you are small. Not rocket science!)

tape measure

ruler
________________________________________ ____
IMPORTANT
Foam rubber is bendable and rather elastic. And these measurements assume that you are wider at the shoulders than at the waist. So a lot of 'GUESSTIMATION' was at work here....treat the tutorial as a guide, not a bible, and accept that most measurements would only be correct to within +/- 2cm!!!

This was a rushed job completed in a day, so if I make improvements to the design, I will post a new blueprint.

Good luck!
Add a Comment:
 
:icontheblackmanbrony:
TheBlackmanBrony Featured By Owner Jan 15, 2015
Do you have like a step by step process on how you did this exact one cause im working on one like this for a con in May real soon!
Reply
:icongreenzaku:
greenzaku Featured By Owner Jan 20, 2015
I'd recommend doing the main front/back piece first and then trimming the side bits to the right size, but other than that, its all just cut and paste.
Reply
:icontheblackmanbrony:
TheBlackmanBrony Featured By Owner Jan 23, 2015
ahhh kk thanks! ^^
Reply
:icondomorussell:
Domorussell Featured By Owner Oct 27, 2014
This is awesome. I'm going to make this my Halloween costume.
Reply
:iconmixxi90:
mixxi90 Featured By Owner Sep 5, 2011  Hobbyist Artisan Crafter
if you wanna cut foam easy use a electric knife like this : [link]

we always use it for .. whats english word.. this french hard long white bread rofl to chop it in pieces

you get it really nice^^ no puckets anymore and else use a dremel
Reply
:icongreenzaku:
greenzaku Featured By Owner Sep 5, 2011
Thanks, I'll bear that in mind.
Reply
:iconmixxi90:
mixxi90 Featured By Owner Sep 6, 2011  Hobbyist Artisan Crafter
your welcome^^ me and my friends also struggled a lot with this problem until my grandma told me of this XD

and now it goes vroeeemmm!!
Reply
:iconzofraniro:
zofraniro Featured By Owner Jul 31, 2011  Hobbyist Writer
What else would work well besides the foam/rubber stuff? It looks stiff. Otherwise, good job!
Oh. The requirements of measurement... I'm not even 95 pounds, since I'm so tiny, would I need to reduce the size any?
Reply
:icongreenzaku:
greenzaku Featured By Owner Jul 31, 2011
There is similar foam material that you can buy from camping stores as camping mats. I would say you could probably get away with thinner material too because of your size...you might even be able to get some thinner rubber material that is used for floor mats or friction mats from a hardware store. Otherwise you can simply substitute your own X,Y,Z etc measurements in here.
Reply
:icongunsguru:
Gunsguru Featured By Owner Mar 29, 2011
Hey, curious, how big was the piece of foam?

Our local Big Lots is selling large pieces of foam for 18$ a roll at 46inx93in. Curious if maybe one of those would be around roughly what you used.
Reply
:icongreenzaku:
greenzaku Featured By Owner Mar 30, 2011
It sounds like it, I used a 1m x 2m piece for the main panels and 2m of thinner mterial for the straps. But you might like to get more...I weigh about 110lbs only '^_^
Reply
:icongunsguru:
Gunsguru Featured By Owner Apr 3, 2011
Yeah, it was a spur of the moment thing, I'll try and make it work and work well.
Reply
:iconrohaam:
rohaam Featured By Owner Jan 9, 2011
I hope you dont mind me makin use of this :O
Reply
:icongreenzaku:
greenzaku Featured By Owner Jan 10, 2011
It's up for everyone to use ;)
Reply
:iconrohaam:
rohaam Featured By Owner Jan 10, 2011
Thank you! Ill post pics of it when its done, If I have enough time I might change the box though :O (no offence ^^: )
Reply
:icongreenzaku:
greenzaku Featured By Owner Jan 11, 2011
No prob! This was a rushed cosplay with all actual work completed within 24 hours, so given a chance, I'd recommend better ;)
Reply
:iconrohaam:
rohaam Featured By Owner Jan 11, 2011
I cant really see what the big stuff is, Is that the foam rubber? (yea I am not really good at geussing XD)
Reply
:icongreenzaku:
greenzaku Featured By Owner Jan 11, 2011
Yup. Its from a store that sells rubber sheets for insulation, linings, waterproofing etc. There should be a wide variety of textures and thicknesses available in such stores if you prefer something other than what'[s been used here.
Reply
:iconrohaam:
rohaam Featured By Owner Jan 11, 2011
How do you think larp foam would work in this case? (in holland we have a store that sells larp foam)
Reply
:icongreenzaku:
greenzaku Featured By Owner Jan 11, 2011
I'm not sure what larp foam is...
Reply
(1 Reply)
:iconkyattsuai7:
Kyattsuai7 Featured By Owner Dec 15, 2010
Wow, except for the overlapping flap on the front, it looks spot-on. How thick is that foam rubber? It looks like it's about 1"/3cm.
Reply
:icongreenzaku:
greenzaku Featured By Owner Dec 17, 2010
I think the main body of it is about an inch thick - I don't have it with me at the moment to check precisely.
Reply
:icontowercorp:
TowerCorp Featured By Owner Dec 4, 2010  Student Digital Artist
How the heck did i manage to miss this for so long?
You, sire, are my new internet idol just for posting this guide. *-* no, really, this is going to be incredibly useful! I was worried i would never manage to finish it. Thank you SO MUCH! :D
Reply
:icongreenzaku:
greenzaku Featured By Owner Dec 4, 2010
Thank you! My two pet rats chewed part of it to shreds one day and I will need to remake mine though =_=. But i'll take it as an opportunity to refine the pattern and try and make it a little sleeker.
Reply
:iconfevereon:
fevereon Featured By Owner Nov 10, 2010   Artisan Crafter
That rubber material looks great, especially for design of TF2 :)

Much thanks for sharing!
Reply
:icongreenzaku:
greenzaku Featured By Owner Nov 11, 2010
Why thank you! :D
Reply
:icondarthmar:
DarthMar Featured By Owner Nov 8, 2010
Also: if you're using craft foam to make the vest, there's hot glue sticks they make specifically for it now... :D That and duct tape saved a friend's Sephiroth cosplay
Reply
:icongreenzaku:
greenzaku Featured By Owner Nov 9, 2010
I used a contact adhesive that came in a tube that was specifically listing 'foam rubber' amongst the materials it could be safely used on. :)
Reply
:icondarthmar:
DarthMar Featured By Owner Nov 8, 2010
Oh YES! I can now either a) add a femmed up (and decidedly white) Demo to my cosplay list or b) make it for a friend and have him do it... :D

Thank you!
Reply
:icongreenzaku:
greenzaku Featured By Owner Nov 9, 2010
Thank you! :D
Reply
:iconkoleniko707:
koleniko707 Featured By Owner Oct 6, 2010
This'll be perfect to use when I get to Demoman on my cosplay list! Thank you! :love:
Reply
:icongreenzaku:
greenzaku Featured By Owner Oct 6, 2010
Thank you! Its a bit of a rush job though, so maybe its better to take it as a general guideline and be flexible when making your own.
Reply
:iconlabassistant008:
labassistant008 Featured By Owner Feb 25, 2010
Of what I have seen, this is one of the most best Demoman's vests I have ever seen!

And I think there's way too less demoman cosplayers out here D: We need more demomen! xD
Reply
:iconmatarioshka:
matarioshka Featured By Owner Feb 18, 2010  Hobbyist General Artist
FANTASTIC work! I love it! :D
Reply
:icongreenzaku:
greenzaku Featured By Owner Feb 19, 2010
Not enough people cosplay Demoman
Reply
:iconstich76:
stich76 Featured By Owner Dec 21, 2009
Awsome, I always wanted Demo's vest.
Reply
:icongreenzaku:
greenzaku Featured By Owner Dec 21, 2009
Feel free to modify this...its nly a rushed design and its awekward to put on and take off (have the wriggle through the bottom hole) ><
Reply
:iconstich76:
stich76 Featured By Owner Dec 22, 2009
Yeah, the Demo vest looks like it'd be rather stiff. Mainly I'll be using this as a referance on where to put what.
Reply
:icongreenzaku:
greenzaku Featured By Owner Dec 22, 2009
*nods* I wiggled into it from the bottom, but then I'm barely 115 lbs...

That's why I left some of the measurements as variables. I would be glad to see your improved design!
Reply
:iconskyebd:
SkyeBD Featured By Owner Dec 21, 2009
nicely done.
Reply
:icongreenzaku:
greenzaku Featured By Owner Dec 21, 2009
Thank you! XD
Reply
:iconspacesmilodon:
SpaceSmilodon Featured By Owner Dec 21, 2009  Student Digital Artist
Oooh cool :0 it came out really nice too, very accurate C:
Reply
:icongreenzaku:
greenzaku Featured By Owner Dec 21, 2009
Eh...not really. The arm and neck holes are too large as this was not made to be adjustable,this can be fixed in a later version which could be held closed with velcro; and the pouches I am planning to totally redo. :)
Reply
:iconspacesmilodon:
SpaceSmilodon Featured By Owner Dec 21, 2009  Student Digital Artist
Yeah, but those are small details. You really have to pay attention to see those ;)
Reply
:iconundistilled:
Undistilled Featured By Owner Dec 19, 2009
Cool. :)

*cue jokes about turning ones self into a giant black rubber*

:lol:
Reply
:icon0armoredsoul0:
0ArmoredSoul0 Featured By Owner Dec 19, 2009  Hobbyist Traditional Artist
WHOA, nice job!
One day's work, and kick f'ing ASS!
X3
Reply
:icongreenzaku:
greenzaku Featured By Owner Dec 19, 2009
I was surprised it came out in the end despite some innacuriacies :)
Reply
:icon0armoredsoul0:
0ArmoredSoul0 Featured By Owner Dec 20, 2009  Hobbyist Traditional Artist
Well, it was your first time building it, and it was to your own bodily frame, so inaccuracies to the model are to be expected to better fit the wearer.
It really did come out brilliantly.
^^
Reply
:iconsplicermedic:
SplicerMedic Featured By Owner Dec 19, 2009
awesome!
*happy dance for you*
Reply
:iconfudoko0114:
Fudoko0114 Featured By Owner Dec 19, 2009  Hobbyist Traditional Artist
:iconheavyisamazed:
Reply
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