Tutorial – Make your own Vault Suit

vault-boyRecently on de.bethblog.com, our German community manager, Eva Sykora, worked with Bethesda fan/cosplayer Corroder on steps for making your own Vault Suit. Learn all the steps, in English, below…

Many of you may already be familiar with the cosplayer Corroder for his Keeper costume inspired by The Evil Within. For Gamescom this week, he’s worked on a new project: creating his very own Vault Suit for the 111 Vault Boys & Girls event during the show.

How did he make his suit? Find out after the break…


  • 1 set of coveralls in your size
  • approx. 20 inches of yellow fabric (suitable for ironing)
  • approx. 20 inches double-sided iron-on fleece (or hemming tape—this is a very liberal amount in case anything goes wrong )
  • 1 iron
  • 1 pair of scissors
  • 1 ruler or protractor
  • some baking paper
  • something to draw with (tailor’s chalk, soap, pencil)
  • your computer and printer


1 material
First, you’ll need to wash the coveralls and let them dry thoroughly. If your costume is to be washable (recommended!), you should also wash the yellow fabric beforehand. The color in many fabrics will run in the first wash.

Now create a template for your Vault number. Use a word processor to type the number in the desired font and print it out in the required size. A more exact, but also more time-consuming method is to take a screenshot and trace the number directly. Then cut the number out.


2 schablone für nummer

For the stripes on the chest and the collar (and also the hips in Fallout 4), place your costume flat on the floor. Set the baking paper on the chest and trace the seam along the zipper and the collar. Now draw a second line, parallel to the first, using the protractor (or ruler), and leaving a gap of your desired length between them. Then simply cut it out and your stripes template is ready.3 schablone für streifen

Now iron the yellow fabric—paying attention to ironing instructions and possibly testing a small section first to see how hot the iron should be set—to make it flat and smooth. Then place the number back-to-front on the reverse side of the fabric—the side that won’t be seen—and trace around the template. Tip: It’s best to use chalk or soap, as these can be easily washed out.


4 anzeichnen

From this point on there are 2 variations:

Simple version: you cut the number out now. However, the fabric may become frayed after washing.

More elaborate version: you draw a second edge, approximately ½ inch outside your first line. Now cut into the edge with the scissors, almost to the first line, in a place where there are curves or corners in the number or on the collar. This is to make it easier to fold in the fabric without making large wrinkles and lumps. The edges are now carefully ironed.

5 zugabe umschlagen,vorbügeln

Now the iron-on fleece needs to be cut to size. Place the template on the side with the baking paper, draw around it and cut out the shape. However, this time no edge is added, just cut out the number. Note: For the elaborate take, you’ll need to cut out everything twice.

Next, the iron-on fleece is attached to the fabric.

For the simple version, place the iron-on fleece on your ironing surface with the protective foil facing down, and place your cut out yellow fabric number on top. Now iron both sides briefly to attach it. Pull the protective foil off and iron both parts to stick it firmly onto your jumpsuit.

For the elaborate version, an additional layer of iron-on fleece is used. Take your cut out number and place it on the ironing surface with the visible side facing downwards. Place one of the fleece cutouts under the ironed edges and fold the edges back over it. Now attach the iron-on fleece by placing some baking paper on top and ironing over it briefly.

7 bügelvlies auf rückseite

You now proceed as in version 1. Take the iron-on fleece with the protective foil facing down, iron on your number briefly, pull off the protective foil and iron it all onto your jumpsuit. Follow the same procedure for the stripes.

There you have it: your own Fallout Vault jumpsuit!

9 nummer fertig

Reader Comments

  1. This is an extremely detailed guide on making a Vault suit. I did not imagine that it could get this detailed to making something as simple as a suit. Also, the blue color appears to blend with the user and it seems rather stylish.

    • In earnest, have you ever been inspired to create things for no other reason than you want to hold “it” in your hands?

      Games with immersive settings like Fallout are Magical (as bleak as they sometimes are) in a very literal sense if you think about it in the right context. They have created a reality that is powerful enough to summon bits of itself into the physical world through our collective desire and ability… If that’s not magic, I don’t know what is.

  2. For a quick way to age any costume, throw it in the wash cycle with a cup of dry dishwasher crystals instead of detergent! For extra wear and natural tear, take a bit of sandpaper to the knees and elbows between crystal-washings. For best results, give the costume 4-8 crystal-washings. Good luck, fellow Sole Survivors!

    *Extra XP*

    Splash your favorite flavor tea onto the armpits and between the shoulder blades for pleasantly fragrant funky stains!

  3. Can someone please help me find the coveralls he uses as all the ones I find have pockets all over it. Any help would be great thanks 😊

    • Use a seam-cutter or a sharp blade to cut the pockets you don’t like off. Just be sure to do that BEFORE you attempt the Crystal-Wash method I mentioned above, otherwise you’ll have some interesting colors going on when you remove the pockets.