Been lurking since October, just signed up this month.
Days before last Halloween I found a discounted "Deluxe Boba Fett Costume" at the local costume shop. Someone had stolen the helmet so the horrible polyester jumpsuit was $25. I decided that for the purpose of getting drunk at a weird basement Halloween party, it would be good enough if I could make a helmet. I usually leave things until the last minute and this was no exception. I left myself 2 days for the whole helmet...
I had every intention of making a shoddy but passable bucket, but when I found this forum and my OCD kicked in, I got a little obsessed.I used the WOF templates and went the resin, fiberglass, bondo route. This is INSANELY inaccurate (didn't even have time for the dent OR the rangefinder) and the dome is a spiney mess but for two days it was as good as I could get it.
SO, since then I haven't been able to stop thinking about fixing my helmet, re-painting to ESB colours and making a full ESB suit. I've been trolling the forums for a couple weeks researching all the templates and productions methods I can and I'm doin' it. I'm goin in'.
My overall idea is to Pep/Resin/Bondo the male mold of everything and then vacuum form from there. I went and picked up some ABS from a supplier here in Vancouver and I'm looking into the best approach for building a DIY vacuum former. My main concern is the heating unit at this point. I'm going to try to make something in the vein of the xRobots unit.
My main question is this: I started my Pep gauntlets yesterday, got them resin'd and ready for the bondo stage - Excitedly awaiting greebs in the mail from Darth Vorhees - My intention is to vacuum form these out of 1/8" ABS... Is that too thick? It seems to me by eyeballing it that it might lose too much detail. Has anyone done this with 1/8" and a Pep model? Is this a stupid question? Here's the rough Gauntlet tops I did yesterday:
Stoked to finally be a part of the community and I look forward to bothering you with questions like this in the future.
Thanks in advance for any help,