Counterweight's ROTJ buildSubscribe
  1. Counterweight's Avatar
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    Nov 2015
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    1 Week Ago - Jul 19, 2016, 3:23 AM - Counterweight's ROTJ build #1

    Hello all,

    I just recently "finished" my second cardboard scratch build helmet and have made the decision to jump to the full costume. I'm sure it's going to be a very difficult task, but that's half the fun. This build is going to be a very slow process, especially during the summer, but it'll get there slowly but surely

    If you want to see my second helmet build its right here
    http://www.thedentedhelmet.com/f23/c...h-build-54488/
    I haven't gotten the electronics or visor for it yet, but the build and paint up are finished.

    While waiting for all the necessary electronics I went ahead and started on the gauntlets. I also did this because I want a RC servo to control my rangefinder and I want the controls to be the switches on the right gauntlet

    I couldn't find a ton of detailed threads on how to build these, so I just studied the hell out of google images to put the pieces together. Here's what I have so far

    All pieces for both gauntlets pasted to the cardboard






    To curve the gauntlets I found a can of carpet deodorizer that was a similar width to my arm, got the cardboard damp, and then curved it around the can. I did this with all four layers, then pinched them between cans so they kept their shape as they dried



    After the layers dried I glued the two uppers together and the two lowers together. I did not glue them before bending because I wanted to avoid the top layer of cardboard being warped when bending. Idk if that's how it's supposed to be done but oh well.









    Now putting all the pieces together was interesting... I started by bending and gluing where needed, then I layed the pieces on top of the gauntlets themselves to check the fit





    I noticed a couple of obvious missing pieces



    You can also see the fit of the pieces isn't great above the missing piece either.

    Regardless, I measured the missing pieces, drew them on cardboard and cut them out. Any minor gaps and imperfections will be fixed with bondo so I'm not sweating it at this point

    Here is what I currently have done



    I don't want to glue the pieces to the gauntlets quite yet. I'm going to wait until I have the electronics to do that.

    For now I can coat them with some layers of sealer, and then I will begin working on the left gauntlet while I wait for the electronics.

    It's a decent start. I'm trying to be patient and take my time because I'm not overly talented at scratch building.

    Sorry for such a wordy post, future posts I'll try to explain less so there is not so much reading.

    Once the electronics are installed I'll be able to attach all the parts to the gauntlet and then begin hitting it with some bondo!

    Next update: beginning to cut out and put together the left gauntlet!
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  3. RealMatix's Avatar
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    1 Week Ago - Jul 19, 2016, 4:24 AM - Re: Counterweight's ROTJ build #2

    This is really is a awesome start ! I hope someday i will find the time to make the Gauntlets from scratch. From experience of my helmet construction , i can only recommend to remove the paper templates from the cardboard. It will probably get waves and protruding fibers when you start painting it.
    I'm not overly talented at scratch building
    I don't thing so

    Cheers RealMatix
  4. Counterweight's Avatar
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    Nov 2015
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    1 Week Ago - Jul 19, 2016, 10:44 AM - Re: Counterweight's ROTJ build #3

    Quote RealMatix said: View Post
    This is really is a awesome start ! I hope someday i will find the time to make the Gauntlets from scratch. From experience of my helmet construction , i can only recommend to remove the paper templates from the cardboard. It will probably get waves and protruding fibers when you start painting it.

    I don't thing so

    Cheers RealMatix
    Thanks for the support. The paper is actually an issue that I've encounter before. On my first helmet build I just traced the templates and it didn't work out well. For my second I used normal white glue, and when applying my water/sealer mix I had the issues you referred to. For this one I have actually used the gorilla glue to paste the templates on, so they're not coming off clean anytime soon. But as long as the first layer of sealer isn't mixed with water, I shouldn't have any issues.

    Like my helmet, once it is sealed I no longer have to worry about the paper swelling or bunching up

    Maybe after my gauntlets I can try it another way though. Thank you for the input! I appreciate all the constructive criticism I can get! Haha
  5. Magnavis's Avatar
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    1 Week Ago - Jul 20, 2016, 11:52 AM - Re: Counterweight's ROTJ build #4

    You're doing the whole thing now?! Awesome job so far! Good luck
  6. Level3Fett's Avatar
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    1 Week Ago - Jul 20, 2016, 1:53 PM - Re: Counterweight's ROTJ build #5

    Glad to see you back at it...you're a scratch pro now..
  7. 5 Days Ago - Jul 23, 2016, 3:36 AM - Re: Counterweight's ROTJ build #6

    ha, here we go good start you will have no problem getting this going
  8. Counterweight's Avatar
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    1 Day Ago - Jul 27, 2016, 5:48 PM - Re: Counterweight's ROTJ build #7

    Quote Magnavis said: View Post
    You're doing the whole thing now?! Awesome job so far! Good luck
    Yeah it's gonna be a slow process but it'll be a fun pet project

    Quote Level3Fett said: View Post
    Glad to see you back at it...you're a scratch pro now..
    Hardly, but thanks!

    Quote Silverstalker said: View Post
    ha, here we go good start you will have no problem getting this going
    Thanks man. Criticism/advice is always welcome
  9. Counterweight's Avatar
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    1 Day Ago - Jul 27, 2016, 5:58 PM - Counterweight's ROTJ build #8

    I've made some decent progress on the gauntlets. First, I sealed the various parts of the right gauntlet. I'm still keeping them separate so that I can install the electronics once I'm able to get them. So in the meantime, the right gauntlet is done



    Next up, cutting out the pieces of the left gauntlet and trying to figure out how to put them together. Not many references or tutorials on how to do it unfortunately, so still relying on Google images



    I think I got pretty close. Hopefully bondo can rectify any issues



    Now for the flamethrower box... I had more trouble with this than I should have. But I think I got it



    Quick question... Anyone know how/where to place this piece? I can't find any references for it and I don't want to put it in the wrong spot



    Anyway, aside from that piece as well as a couple other pieces that I have no idea what they're for, it's pretty much done. This is what I have so far









    (Those pieces for the right gauntlet aren't attached, just resting on top. Same for the flamethrower box)



    So that's where I'm at right now. Hopefully one of you can help me with where that piece goes. Also, anything else I've messed up feel free to correct. Next to do, seal the left gauntlet, bondo the left gauntlet since most of it is attached, and eventually get the piano hinges and electronics in the gauntlets so I can move forward.
    Last edited by Counterweight; 23 Hours Ago at 7:57 PM.
  10. 13 Hours Ago - Jul 28, 2016, 5:38 AM - Re: Counterweight's ROTJ build #9

    Looks great so far. I will say this the right gauntlet, the part where the top hose will attach I would look at beefing the area up with something, that part will take the constant force from you bending your arm one way and the hose pulling down the other, that area is a week link in the chain and can brake off!

    Also whip cord housing on the right gauntlet is to far forward, move it back a bit, if you look at the link its a good base line as to where it shoukld go..
    https://www.google.co.uk/search?q=RO...yoTu7WVFPpM%3A

    on the subject of that area that will also need beefing up, again it has two hoses on it that create a lot of force....

    I used a shim of wood to make a sort of spine in them areas hel in with nuts and bolts just to make it more solid..



    oh and that part you can't find a home for is the spacing tepmplate for the flame thrower apertuers thats all it is.
    https://www.google.co.uk/search?q=RO...2QK41uMvivM%3A
  11. Counterweight's Avatar
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    Nov 2015
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    10 Hours Ago - Jul 28, 2016, 9:10 AM - Re: Counterweight's ROTJ build #10

    Wow, thanks for all the tips, this is great info. I have plenty to work on now! Updates soon

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