Many elements of this costume were purchased: hat, vest, t-shirt, fingerless gloves, red bandana, pants, and boots. The patches on the vest were purchased from patchzone on eBay. The velcro patch on my hat came from WsbShop on Etsy.

To construct the smartgun I began with a set of STLs available on Thingiverse created by Zagadka. These did require some scaling in MS 3D builder and I further used 3D Builder to cut many of these pieces so that they could lay flat on the print bed and not have details obscured by supports. I then cleaned up these pieces and reassembled them with epoxy, using some threaded rod to reinforce some of the thinnest parts near the forward and rear grips. A PVC pipe was attached as a coupler for the pivot joint. Coaxial cable was added for the 'video link' and battery. Foam bicycle grips were fitted, just like the original prop.

Materials: PLA filament, steel all-thread, coaxial cable, foam bicycle grips, JBWeld plastic bonder epoxy, Apoxie, acrylic paints.
Notable tools: Microsoft 3D Builder, Ender3 FDM printer.

In the orginal film, the combat harness largely incorporated a Stedicam vest and arm, but those are expensive! Thankfully, A/V folks are resourceful and there are several guides for how to build something similar on a budget. I followed this one to build the 'arm' from PVC and made the brackets from aluminum plate with the included template. The main difference I added was to cut channels into the PVC pipe so that the springs could be placed inside. I also mounted it to a flatted piece of PVC riveted to a 2" pistol belt.

I made the 'vest' with EVA foam (heat sealed and Plastidipped), 2" nylon strapping and a number of buckles.

Unable to get my hands on an original Raytheon headset, I spent a fair bit of time figuring out how the original pieces would fit appropriately on a different set of headphones. The STLs were provided by a helpful member of the Aliens Legacy forums who has asked to remain anonymous so that their inbox doesn't get filled up with requests. A quick search of the threads and some polite questions will probably get you what you need though. Interestingly, these files did not include the camera lens, so this part came from a helmet cam designed by mkauffman41 available on Thingiverse. The 'glass' of the lens is a clear piece of plastic film. I made the boom mic by modelling a few simple parts in 3D Builder and fitting them to an aluminum tube. For the cable/plug, I coiled a couple pieces of wire around a wooden dowel and hit it with a heat gun. I chose to connect this differently than done on-screen to avoid possible snags at crowded conventions. I did keep the headphone jack so this does plug into the vest.

The STLs for the shoulder lamp were also provided by a member of the Aliens Legacy forum. I installed some LEDs in the lamp head, covered with diffusion foam, and wired into a battery tray in the main box. The back panel is held in place with magnets (and usually another piece of duct tape).

Overall, I managed to use a lot less duct tape than was used in the original film, but I used it in a few spots as a fun reference :)

Materials: PVC, aluminum plate, springs, PLA filament, aluminmum tube, EVA foam, nylon strapping, ABS buckles, LEDs and wiring, JBWeld plastic bonder epoxy, Apoxie, PlastiDip, acrylic paints.
Notable tools: Microsoft 3D Builder, Ender3 FDM printer, soldering iron, bandsaw, Dremel.