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Picture of Sergeant Calhoun

Sergeant Calhoun, you're Dynamite Gal from Hero's Duty who also just happens to have the most tragic backstory every written. This is a fabulous costume to wear, and people love it! Though I do warn you that it will take a bit of work. If this scares you off and makes you wanna to go pee-pee in your big-boy slacks, then keep it to yourself!

Step 1: Costume Breakdown

Let's break down all of the pieces for this costume (are you ready for this?):

  • Undersuit
  • Corset
  • Chest-piece (this is big, let's break it down further)
    • Chest
    • Abs
    • Back
    • Shoulder straps
    • Collar
  • Pauldrons (shoulders)
  • Upper Arm Armor
  • Bracers (forearms)
  • Hip and Thigh pieces (4 of them)
  • Greaves (lower legs)
  • Shoes
  • Belt
  • Gloves
  • Wig

Whew! Got all of that? Good.

Now I like to order things on what I feel is most important. This will help you budget your time and money on a costume like this so that when you run out of one or both of those resources, you can still have something.

Must haves (Top):

  • Some form of undersuit
  • Chest-piece
  • Bracers
  • Leg armor
  • Shoes


  • Upper arm
  • Pauldrons
  • Thigh pieces

Nice Details:

  • Gloves
  • Corset
  • Belt
  • Collar
  • Gun
so awesome! I must have missed you at salt lake comic con.
jec04351 year ago

Might I also add.. I love that you elect to wear flips flops each year with your own costumes Joe! hah! (Flip flops rule!)

joecooning (author)  jec04351 year ago
That's funny you noticed. I did opt for shoes later, though, since it started raining.
jec04351 year ago

Fantastic write up! Thanks for sharing all the details. Sometimes the Instructable takes as much time as the costume. Wow.

CalebGreer1 year ago

That's dope. Great work!

jfarro1 year ago

Wow! Really well done instructable, and the final outcome is dead on. Great work, and loved the family pics at the end to see you all dressed together...that's awesome :) Fav'd and voted!

KeifD1 year ago
Great stuff!! Lots of work put in there. Inspiring! I got some foam here I might just use for armor. ;)
joecooning (author) 1 year ago

Thanks everyone. We had a lot of fun with this.

You did such a good job!

Swansong1 year ago

OMG I love this! She's one of my favorite characters and your cosplay is spot on!

This is amazing! And you all look great together :D

That is so awesome! I especially like that you got the whole group together.