Gordon Freeman was my second ever armored costume to make.
I decided that I wanted to make a bigger costume for Anime Expo 2013, and so I searched around for ideas. I had started replaying Half Life, the game I always played as a kid, and then I got a little obsessed for a while.

So, for Christmas, I bought myself a bunch of EVA foam and a heat gun and started making the suit!

All of the armor is made from EVA and craft foam. The chest, leg, and groin part are all EVA. The rest is craft foam. I used a thicker craft foam for the arms, since I wanted it to look like the EVA foam, but not as super thick.

I made the crow bar using a PVC pipe, spray painting it, and then pool noodles for the steel parts. I think eventually I want to remake it out of Worbla someday.

I wired the back of the chest piece with LED lights and put the switch in the front so I can easily turn them on and off.

The costume took around three months to make, overall.

In 2013, I decided to come back to the costume and touch it up, aging all of the pieces and sealing them, since I had never done that before.

I ended up winning Best Hero at Detroit FanFare 2013!