Lord Zedd | 2025 Halloween Costume Contest
This custom-built Lord Zedd cosplay was entirely hand-crafted from the ground up. The armor and helmet were constructed using a combination of EVA foam, foam clay, and styrene, then meticulously wrapped in chrome silver vinyl to achieve the character’s signature metallic finish. Every armor piece was crafted using the same process for a cohesive, screen-accurate look.
The exposed musculature was sculpted from carved upholstery foam, coated with a thin layer of foam clay to create the realistic anatomical texture of Lord Zedd’s skin — designed to resemble raw muscle tissue brought to life through careful carving and paint detailing.
Completing the ensemble, the iconic Z-Staff was fabricated using EVA foam and PVC pipe, also finished with chrome vinyl wrapping to perfectly match the armor’s reflective sheen.
This build showcases craftsmanship across foam fabrication, vinyl application, sculpting, and finishing techniques — bringing one of Power Rangers’ most iconic villains to life in full, menacing detail.
https://youtube.com/shorts/z3bQPceDyIY?si=gJc9F0oel9NIMYgH
https://youtube.com/shorts/z3bQPceDyIY?si=gJc9F0oel9NIMYgH
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