The peacemaker

The base model was taken from MyMinifactory.com by user Jeff Lagant's design. We modified the grip to be hollow, created a back handstrap that better matches the in-game model, and modified the trigger-guard area to a sharpened bevel more akin to the in-game model. The laser sight was bored out and a cut-down glow-stick was placed to diffuse light from an installed led, which had the internal wiring run up through the barrels, through the cylinder (and through a barrel 'plug' stabilizer' that kept the gun straight), through the hammer piece and into the hollowed out grip. Inside the grip was a rocker switch connected to a CR2032 battery source, which powered the laser sight, and two leds that illuminate the small windows on either side of the grip through a thin lexan piece.

After hours of sanding, polishing, spot putty, more sanding, and bondo work, the piece was moved onto airbrushing. A base coat of filler primer was used, and sanded to get a nice smooth finish and give the paint something to grip onto. Using Model Master enamel paints, each piece was individually airbrushed and polished. All metal areas were sealed to prevent rub-off. A custom vinyl mask was created to create the stars and stripes motif on the grip, which was then clear coated to prevent wear off from constant grip and handling during convention walks.

Accessories

Bullets, Flashbangs, oh my! The bullets were 3d printed, sanded and painted with a brass-metal paint and mounted to the hat and assembled on the ammo belt piece the character wears for those fast reloads. The flashbangs were 3D printed, and plastic tubes found at our local dollar store were cut to size for diffusing a mounted led inside, with a rocker switch hidden on the clip-side for easy off-on functionality. The flashbangs were primed and then airbrushed using model-master paints.

The chaps were made using a faux-leather fabric and sewn in-house, with the buckles 3d designed and printed, and the final pieces attach to the cosplayers belt, and with snaps and velcro around the back of the knee.

The hat!

No cowboy, cyborg or otherwise is complete without a hat. After searching the internet and local stores, we could not find a close enough existing hat to match the huge brim and style of McCrees battle worn hat, so we decided to make it! Using EVA Foam (floor mats!), we sanded off any texture, created a template based upon an overhead view of the in game model and cut out the base of the brim. Measuring the approximate width of Ryan's head (the cosplayer who donned the costume) the upper part of the head was created with EVA foam, and the very top with thinner craft foam.  The approximate wear and tear points on the hat are also pulled from the in-game model design to be as close as possible, and a thin line was cut around the brim and heat gunned to create the overlapped edge effect. A faux leather material was purchased to create the band of the hat for the blackwatch badge and bullets to be mounted onto. The badge itself was custom modeled and sculpted, then 3d printed, polished and resin cast for final use (Copies of this cast will be available in our store soon!).

The armor

The armor! Can't be a cyborg cowboy without it! The chest pieces, back piece (which was is only partially visible when donned), ab piece, and kneepad were all constructed from EVA Foam floormats, sanded, shaped and sealed to create the final piece. A combination of spray paint and model-paint was used. For the pectoral pieces, a window was cut in each side for lexan plastic to be placed and leds were mounted inside for the yellow glow of McCree's chest parts. The bracer was custom modeled and sculpted in 3d, then 3d printed and polished up before being airbrushed and assembled. The Elbow piece was also 3d designed, printed, and heavily bondo-ed, and polished, with lexan pieces cut and mounted on either end for LED lights to be diffused out around the central rivet-like joints. A small piece of sprinkler stake tubing was used for the connecting cable from wrist piece to elbow and secured with small magnets for easier donning of the gear.

Pipe connectors for the exhaust/muffler-like parts were 3d designed and printed, mounted to the foam ab piece, and pipe insulation foam was used for the pipes themselves. After some con-wear and tear, it was found that the pipes needed to be secured via nylon webbing around the back, otherwise they would not stay in place with the internal wire structure installed.