Hi everyone, well as usual I'm working double overtime in the shop (one of these days I hope it'll pay off lol) and have decided to move on to the next portion of the Fett style armor that I've been producing. Not a whole lot of progress in the way of pics, but these few were a LOT of work and time involved. These are based exactly off the WOF gaunt templates with some size and curvature references taken from my own gaunts that I purchased a while back. Take a look:
Bottom half shell of the right gaunt
And the bottom half shell of the left gaunt...wound up having to fix the curvature on this one after discovering that it was too large at the wrist
After I got those two knocked out and a master pulled, I moved on to the top half shell of the right gaunt...a HUGE thanks to Alan of WOF for making these available to us. I can't tell you enough how easy his templates have made my life in the last 4 months...they're super accurate too from what I can gather. Coupled with pics of the actual screen armor from the MOM exhibits, I have learned quite a bit about this armor. I had to make this portion of the detailing out of a thin wafer wood (or whatever it's called) for sturdiness to be able to withstand the pressure of the vac pull
So what I did was print out the templates, traced them onto the wood, cut the pieces all out with a numbering system corresponding to the templates, then started assembling taking into account the thickness of the wood (very important). Hot glue was my good friend for this portion of the build
That's where I'm at right now...between filling orders and trying to squeeze in time for a personal life as well as keep up on chores and the like, it has been quite a challenge. I hope to have more progress very soon.
Everything looks great so far!
Here's another quick update:
Made some more progress today...not much, but here's some pics
And after two failed attempts at a master pull, I finally got this! (third time's a charm)
For the next step I'll fill it with some Ultracal plaster and tidy up that mold as well as add some details that are not in this pull...then pull a final master. After that I'll have to pull a test piece to see how it matches up with the bottom part. That's all for now kiddies...stay tuned
Thanks CT 1127
Made some more progress. Here's the pics:
Fresh out of the plastic
And all cleaned up (burned out my third dremel this year lol). This part was actually a royal pain in the *BLEEP *and far more time consuming than I wished it to be, but I did finally get it done.
As you can see there's quite a bit of a difference
So I was kind of ancy about seeing this pulled so I got some .030 styrene (more on that later) to do a kind of test pull. It came out ok. I'm not entirely happy with it but at least I got to see how sharp the details were going to come out with a thinner gauge. I'll likely use this one as an inner shell for the master and pull another one from .060 for strength and place this one inside of it for pouring a cast since the thinner stuff has better detail and it will save me time in the future in cleanup after a pour.
I'll probably be pulling these out of 1/8" inch for production since I can't seem to get my hands on any .090 smooth/smooth ABS, but we'll see. Here are the results:
That's it for now. I'll be getting started on the right gaunt next week hopefully
Oh man, this is so exciting. It makes me want to try vacuuforming. Looking good!
Thanks Elusive (love your avatar by the way)
Another progress report for you all:
After cutting out the halves of styrene, I held them together to see how they match up. I was pleasantly surprised to see that either through Alan's design (which is more likely) or through my fumbling, I was actually able to get them to match up end to end (after trimming them of course).The recessed areas all line up, so these guys are ready to go! The next step will be to experiment with the plastic to see which one works best for these gaunts. For now I'll set these aside and get to working on the left gaunt top half.
Getting started on the left gaunt. Here's pics:
I don't think I have ever seen someone sit down and bust out a project like this. It usually involves clay and lots of sculpting. Amazing to watch your approach!
Very cool approach! This is looking great, man. Keep it coming!
Thanks guys!! And a reply from the board owner himself! I've been pretty fortunate to have a job recently with a lot of days off per week that has allowed me to get as far as I have in such a relatively short time.
It's been quite a long road on this and I still have plenty left to do, but I've definitely learned a LOT along the way. Not only just about the armor, but about sculpting and vacforming as well. I have pretty much nil experience with sculpting in clay. However, I have been scratchbuilding models for quite a few years now which has spilled over into my costuming....I figured I would try and see if I could apply those skills on a larger level and with sculpting. So far it seems to be working I think. Being outside the box definitely helps with thinking outside of it and I'm sure to a lot of people my methods are pretty unorthodox.
I'm definitely a far cry below BM, FP, Cruzer and all those other talented dudes, but thanks to them I have learned quite a bit about the process just by looking at pics they have posted here and there. Also Alan of WOF's templates have been a HUGE help in all this...so credit must go to those guys as well for inspiring me to take the plunge. Thanks for everyone who's been watching this thread, and stay tuned!!
I'm glad you like my avatar . I'm really liking your armor. Are you a Robert Venosa or Cynic fan? Both?
I'm not familiar with them but very interested in finding out who they are. Send me a link so I can check them out!
Got a little more progress to share with you all. Same process on the left gaunt as with the other one.
Did some cleanup on the piece with files. I was pretty please with the results. I got some nice sharp corners and edges:
After an initial test pull, I had problems getting the mold out of the plastic. That really wasn't what I needed at this point but what can you do? *:-\ *I'm stubborn and won't quit until I figure it out so I decided to add some wood flares and angles to help out with the severe undercuts that are on this piece. (I'm guessing by looking at the exhibit pics of the original screen used gaunts, that this left gaunt was not vacformed because the edges on it are extremely sharp.... so it's shape is going to pose some problems, but I think I can work them out). I also added some bondo on one side to smooth out the transition between the boxy parts and the round gauntlet curve. I think it looks a lot better and more natural. I also went back and did the same to the right gaunt. Take a look:
And the right gaunt, (still needs to be sanded):
Unfortunately it's been slow going on this the last few weeks because I recently got my old job back from which I was laid off over a year and a half ago. (yay) But the schedule has not been very conducive to sculpting armor (not to mention filling orders...those I have been able to keep up on because I make sure I get those done before moving onto sculpting projects). I'll keep plodding away on this because I am SO close to finishing the clam shells
Got some more progress pics for you all:
Finished up fine tuning the right guant -
And the final master pulled for the right gaunt:
On to the left gaunt -
Some more sanding and fine tuning:
And the final master pulled for the left gaunt -
A test set pulled of the left guant (.030 styrene like the right gaunt)
Just got a few minor things to tweak and these should be good to go. Then I can get started on the left gaunt flame thrower and the accessory piece for the outside of the right gaunt. I talked to my plastic supplier today and he told me I should be getting in the special order plastic trial pieces for me to test out. Hopefully they'll work out well and I get the results I'm looking for, otherwise it'll set this project back a few weeks till I can find a plastic that I'm happy with. I"m also looking at doing a high vac pump for the vac table so that I can get some sharper pulls on these. Stay tuned!
Here's a couple more pics of the test pieces fitted to me.
Left Gaunt -
Right Gaunt -
Those gauntlets looks great!
They gave me an idea for when i start making my fett costume.
So many people on these forums are so helpful with their hints n tips, seem to be a great community.
OK everyone, I've got some more progress pics for you all. I went to the plastic supply place today and picked up the new plastic that I am looking at (here's the pdf file link - http://boltaron.com/films/PDF/1165.pdf) and I have to tell you that this stuff is AWESOME!!!! I love the way it forms and it is baby smooth. I pulled the set below out of .090 and it worked like a dream! The only downside to this plastic is that it gives off some really nasty fumes so I'll need to make sure I start wearing my respirator.
At first I was expecting it to droop the same way as the ABS, and at first it did. Then I left the room and came back only to find that it had actually flattened back out! I was thinking, "What the...?" So naturally I turned up the heat and put it closer to the heating element...still no major droop. I touched it a few times to do a bounce test and it was definitely pretty bouncy. I let it droop some more and then decided to pull it. Needless to say, I'm very happy with the results. This plastic has little to no droop but the flexibility on it is fantastic!...what does that mean to a vacuumforming guy?? Well, the less the droop and more stretch means not only better pulls but also I can now do much deeper, larger pulls on a small table and my webbing woes are all but nil...anyway, enough of that boring stuff. On to the pics: Let me know your thoughts
And here is some texture comparison shots of the haircell .060 and this new boltaron acrylic pvc blend (pulled in .090) It's also much glossier which is nice, but extremely smooth too!
My good bud Jason (Gee2) is gonna be doing a beta test of this set to see how well this new plastic takes paint and adhesives. I'll keep you all posted.
So Will and I have gone back and forth on this project a bit, and being two of only three Fetts' in our garrison we tend to stick together bouncing new ways to better our kits off each other. Last week he asked if I would be available to beta test the gaunts before making them for sale. So the package arrived two days ago;
DSC00106 by darth_who, on Flickr
DSC00107 by darth_who, on Flickr
My first thought, holy ****, no packing material! Then after removing them from the bags I realized, holy **** no packing material, because they don't need any. The gaunts are flexible, yet sturdy and hold their shape extremely well despite not being made from traditional material like fiberglass or resin. BTW Will, love the shipping box...
Next up, trimming and sanding...
DSC00109 by darth_who, on Flickr
So the plastic trims up much like ABS, producing quite a bit of dust, that inevitably sticks to every **** thing it touches...
And after some tack cloth and primer...
DSC00110 by darth_who, on Flickr
The new material takes primer very well filling any small imperfections in the plastic to make a really nice, smooth surface to paint.
Now on to some Krylon aluminum matte and some duplicolor automotive high gloss
DSC00111 by darth_who, on Flickr
Nice and shiny :icon_wink:
After they were dry I took each piece and bent, flexed and twisted them (much more than would be expected of a normal troop), and no cracking, flaking or peeling of the paint or clear coat. Tomorrow I'll start the tedious task of masking (anyone that's worked a Fett knows of my pain) and then on to more paint on Monday (if it doesn't rain, again...). At this point in the testing I can say a few things; Will has done his homework. I've owned three set of gaunts since I started costuming as Boba from low end to high, and these are slowly becoming my favorite based on accuracy of the sculpt, ease of work and overall sturdiness and lack of weight of the product. I'm interested to see how the flamethrowers box and hose details are tackled but I assume they will be as good as the shells.
As I get further into the project I'll post more, but for right now, I'll say well done IOA.
Thanks again for helping me out with this Jason! I really appreciate your input as well because I KNOW you know your Fett! Anyway, those are looking GREAT so far!! I can't wait to see the end product brother!
Alright, so the first few layers of paint worked out great, now for a few more. First some yellow for more weathering/masking, along with some dullcote...
DSC00114 by darth_who, on Flickr
Then some claret wine, that was followed up by some more dullcote and more weathering. Again another flex test all around and still no cracking, peeling, flaking, etc. Up next the adhesive test!
DSC00115 by darth_who, on Flickr
Those are looking awesome brother! I'm taking notes on how to paint mine ;D
My apologies for no pics. on this update, but the camera was totally dead and I didn't feel like waiting for it to charge. So the adhesive test; I used two types just to see what would happen. The first was normal Super Glue gel, it held up fine when trying to remove the magnets (what I'm using for closure on the shells) and it also held up after a few collisions with other magnets. However after the fourth time one of them popped off, and then another started to tear away.
Next up the two part epoxy; I used the quick set (1 min) two part loc-tite stuff. After application I tried the same test as above, same results. But on the collision test I got a 50% survival rate vs. the super glue. So I cheated a bit and hit the spots with 80 grit sandpaper, then re-epoxied and also built some on the outer edge of the magnet instead of just the bottom. This seems to have done the trick because they aren't coming off without some serious effort and possible tool involvement
All in all, the gaunts much like the Fett armor produced by IOA are great pieces; this fact along with the fantastic service makes the new gauntlets a very good purchase choice in my opinion. As I upgrade my kit, I will absolutely use Will’s armor and look forward to any other projects/pieces he chooses to produce, especially if he takes on the Imperial Knight project I've bugged him about.