Building the Star Wars Rancor Costume, Part 1

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At this year's Comic-Con, we unveiled The Rancor Project: a huge foam-fabricated costume built by effects artist Frank Ippolito. The project was inspired by a test suit made by LucasFilm for Return of the Jedi, which never made it to the film. To show you how the Rancor was created, we visit Frank's workshop and walk through the design process, starting with a maquette sculpture and patterning by foam fabricator Ben Bayouth. Using these techniques, you can build your own creature costume!
(Note: This video was originally published on 7/25/15 and is re-uploaded here with a few edits. For part 2 of the build, watch here: Thanks!)
Shot and edited by Norman Chan
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Norman Chan
Will Smith
Joey Fameli
Adam Savage
Jamie Hyneman
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