Warhammer Costume
Step into the grimdark future as an unstoppable Space Marine.
The Warhammer 40k Space Marine is one of the most imposing and iconic figures in sci-fi tabletop gaming and video games. Chosen for its massive, battle-hardened aesthetic, this costume represents the ultimate armored super-soldier. The look consists of oversized power armor, a distinctive grilled helmet, and heavy futuristic weaponry like the chainsword.
- Difficulty
- Advanced
- Time
- ~240 min
- Budget
- $150–800
Try it on
See yourself as Warhammer
One clear photo of yourself; we render you in this costume — face untouched, full body, about 20 seconds.
One render, $1. No account needed — if it fails you're not charged. Pricing.
Your photo is sent to Google's Gemini API to make the render and isn't used for training. Renders are AI-generated and labelled.
Want a different costume on this photo, or a whole group in costume? Open the Try-On Studio.
What you need for a Warhammer costume
Short on time? Buy it ready-made
Spirit Halloween sells the complete Warhammer costume — one box instead of 6 pieces.
Space Marine Helmet
A full-head helmet with a prominent mouth grille, circular ear caps, and tinted green or red eye lenses.
DIY: Construct a helmet using printed PDF templates, EVA foam sheets, a utility knife, and contact cement.
Oversized Shoulder Pauldrons
Massive, curved dome-shaped shoulder guards made of thick foam or molded plastic, painted to match the armor.
DIY: Heat-shape large EVA foam half-spheres and trim the edges with foam dowels for trim.
Chest Plate and Back Power Pack
A bulky chest piece featuring an imperial eagle crest, paired with a rear thruster backpack unit.
DIY: Layer EVA foam over a cardboard base, adding plastic cups or PVC pipes to replicate the backpack thrusters.
Forearm Gauntlets and Greaves
Thick, blocky armor segments that cover the lower arms and lower legs, painted in a matching primary color.
DIY: Wrap foam sheets around your limbs, secure them with Velcro straps on the inside, and paint.
Toy Chainsword or Bolter
A massive prop weapon resembling a chainsaw-sword hybrid or a blocky, heavy-caliber rifle.
DIY: Cut the silhouette out of insulation foam, sand the edges, and add cardboard teeth for the blade.
Under-Armor Bodysuit
A solid black, long-sleeve compression shirt and matching pants to wear beneath the armor plates.
Rather not assemble it? See ready-made Warhammer costumes at Spirit Halloween ↗
How to put it together
- 1
Put on the black compression shirt and pants to serve as the dark, flexible joint gaps beneath your armor.
- 2
Secure the leg greaves and thigh plates using internal Velcro straps, ensuring you can still bend your knees.
- 3
Strap on the chest and back power pack assembly, adjusting the shoulder straps so the weight sits comfortably on your torso.
- 4
Attach the massive shoulder pauldrons to the chest plate straps so they sit high and wide, framing your head.
- 5
Slide on the forearm gauntlets, ensuring they overlap comfortably with your gloves.
- 6
Put on the Space Marine helmet, adjusting any internal foam padding so the eye lenses align with your vision.
- 7
Equip your chainsword or bolter prop, holding it firmly to complete the battle-ready silhouette.
Makeup & hair
Since the helmet fully covers your head, makeup is optional. If you plan to remove the helmet, style your hair in a military buzzcut or slicked back, and use gray face paint to create realistic battle scars and grime.
Warhammer for couples, groups, kids & more
- couples
- Pair a Space Marine with an Adepta Sororitas (Sister of Battle) or an Inquisitor.
- group
- Assemble a squad of Space Marines painted in different Chapter colors, such as Ultramarines (blue), Blood Angels (red), and Imperial Fists (yellow).
- kids
- A simplified version using printed foam board armor plates attached to a blue or red hooded sweatshirt.
- Plus size
- The bulky, oversized nature of Space Marine armor is highly accommodating; scale up the foam patterns for a comfortable, imposing fit.
Tips
- Use a wood-burning tool or soldering iron on your foam armor to melt in realistic battle damage, bullet dents, and deep scratches before painting.
- Prime all EVA foam parts with a flexible rubber coating like Plasti Dip before painting to prevent the paint from cracking.
- Apply a black acrylic paint wash into the crevices of the armor and dry-brush silver paint on the edges to simulate worn, metallic battle wear.
- Install small computer fans inside the helmet to prevent the visor from fogging up and to keep yourself cool.
Warhammer costume FAQ
- What is the easiest way to make a Warhammer costume?
- The easiest method is using EVA foam sheets and free online Pepakura (papercraft) templates. You print the templates, trace them onto foam, cut them out, and glue them together using contact cement.
- What are the most popular Space Marine chapters to cosplay?
- The blue Ultramarines are the most recognizable, followed closely by the red Blood Angels, the dark green Dark Angels, and the black Templars.
- How do you make the armor look like real metal?
- Paint the armor with a metallic base coat, then brush a watered-down black acrylic paint into the corners and wipe away the excess. Lightly tap silver paint onto the edges with a dry brush to mimic scratched paint.
Did you know? The iconic chainsword weapon in Warhammer 40k is a brutal fusion of a sword and a chainsaw, designed to tear through heavy alien armor in close-quarters combat.