Winter Soldier AKA Bucky Barnes
Timeline
This cosplay was in August of 2025, and was worked on intermittently over the year, during breaks from college. I wanted to try something more difficult and try out new techniques. Bucky, a long time favorite of mine, was the perfect option for me.
The Metal Arm
I made this arm by taking and customizing a free pattern I'd found online. I adjusted length, sizing, and the shape to fit my needs.
I made a base shape of the bicep with foam sheets, in order to keep the arm as thin as possible. I filled in all of the cracks first, then coated the entire arm with a sand-able caulk.
I did the same thing with the forearm piece, however on that piece I added a zipper going up the inner arm, to make it easy to take on and off.
I then took both pieces and covered them in saran wrap, then a layer of duct tape. I used a bit of 3d renders, cosplay photos, pictures from the movies, and drawings of Bucky in order to piece together where all of the lines and shapes on Bucky's arm should go.
Tracing them onto the duct tape, then carefully cutting it off to make a pattern I was able to cut foam pieces of of.
I then was able to re-coat everything in caulk and begin painting.
The arm started with a black gloss, then a silver. After that I added the red star and a shoulder length glove.
