How to create a Tron Legacy Lightsuit

We are back again with a fresh new challenge for you - which is to create an incredible Tron Legacy Lightsuit for yourself. It would be more or less similar to the costume in Tron movie which will require lot of installations, meticulous adjustments and some practice runs. The plan is to deploy the El wiring in the costume for signifying a powerful combination of beauty and the beast. By executing this project, we can conclude a lightsuit which exemplifies energy (light), and lifeblood (disc) which will became second skin of the wearer.

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Difficulty Level: Moderately Challenging

Time required:

The average time may vary depending upon the circumstantial availability of the resources (as the project demands lot of wiring and electrical equipment) and expertise.

Resources required:

As we mentioned earlier, this project requires that this project will require a lot of resources which include:

Materials:

El wire (29 feet left after the helmet), Black Jeans, Black long sleeve shirt, Blue painters tape, Fishing wire, preferably thin, Gaff tape and Heat shrink tubing.

Tools:

Sewing needle (need to be able to fit the fishing wire through it), Wire cutters, Wire Strippers, Soldering Iron, Solder, "Helping Hands" (they help a lot when soldering the angle wire), Wire (20 gauge) and Light.

How to go about creating it:

Map the Layout

mapping the layout

The first stage will require a lot of skilled job as here the basic design foundations will be laid down. Prepare the blueprint on the suite and determine from where the el wire would be passed out.

Evaluate that positioning the hole shall be placed from where the el wire will be stitched across the suite. A perfect start would give a perfect finishing so assure that you get the right start.

Begin the Layout

2 layout

After that, take out the blue painters tape for flawless positioning of the El wire. Place the el wire over the layout and cover it with tape with a sectional gap of 6 inches. Mark the layout of el wire and remove the previous tape. Use a new tape over the el wire for avoiding imperfections under it. You would have to enter the el wire from the finishing point of the sleeve, slowly covering chest, back and upper back.From one point to another assure that the el wire starts and ends at bottom of the sleeve.

Sewing

3lets get to sewing

Don't worry you don't need to be professional costume designer for performing this task. Just stick to the basic stitching work and you will be there. With a little stitching knowledge, you can knit over and under the el wire to make it firm. The aim of this part is to make the wiring immovable, apply the painters tape across the el wiring after that you perform stitches across the layout and pull the tapes out. As we told you it is very simple.

Soldering the El Wire

4soldering the el wire

This is the stage where the structural integrity of the entire suite will be achieved. Use solder short leads at ends of each stand before actually stitching. By this you will be having el wiring across it and helping hands too. Solder all over it for concluding a new glowing costume.

After that take out 2 separate 20 gauge wire measuring 4 feat and twist them simultaneously. Now, integrate a heat shrink tubing to both ends of the wires and synchronize the tubing over the connection.

Now you will notice that the wires from each side extend to the arms in the interior of the shirt and at bottom, eventually ending up on the left side of the suit. Up next you would have to wire the arms together with the male connector for assuring heat shrink of all connections.

Finishing Touch

finishing touches

Finally, here comes the assembling stage. With the gaff tape, the exposed el wire would have to be placed inside the shirt. This move will avert the light from the shirt.

Quick tips:

Assure that fishing line is not expanded while removing the tape as it will loosen the wire.

Soldering the two short leads with the el wire helps in easier internal connection once its sewn .

A thicker shirt or jacket shall be preferred because the el wire will eventually bend out of shape of the suite. There is absence of positive or negative lead in the El wire so you can use it without any worries.

Things to watch out for:

It would be better to mark the layout of the wire first, then replace the tapes over the el wire for avoiding any imperfection. Other method of sewing everything into place and replacing the tapes will take huge time.Don't start with placing the el wire on the blue painters tape as it will consume lot of time assessing where the wires are going. Ensure that the exposed ends of the wire are covered properly at the bottom of the sleeves or else you can get shocks whenever you touch them.