Jan 31, 2006, 3:18 AM - MS 3 Earcaps
OK I've finished molding all the earcaps and figured out a good cold cast recipe. For those of you waiting on your helmets it will not be long. I'm posting pictures for what you can expect to recieve. The earcaps will come with some flashing, this is the resin that is squeezed out of the mold cavity. I had to do a 2 part earcap mold in order to pull off what I had envisioned for the caps. They will be very easy to clean up, no sanding the backsides, just trim the flashing with a x-acto knife and a quick sand on the seamline. The pieces all plug together nicely. You just need to add a bit of glue. I've cold casted aluminum and the nickel-silver, I would recommend the NICKEL-SILVER for ESB because of the yellowish earcap paint, and the ALUMINUM for ROTJ because the caps have that finish anyways. I quickly polished up half a side on each type for you to examine. I forgot to plug the borden connector in but I'm sure you'll get the picture.
I helped at SDCC '08
Jan 31, 2006, 3:56 AM - Re: MS 3 Earcaps
How about a full nickel helmet? Hah. Just how much would that weigh?
Jan 31, 2006, 4:18 AM - Re: MS 3 Earcaps
It would be REALLY heavy. The earcaps alone feel like solid pieces of metal.
Jan 31, 2006, 8:47 AM - Re: MS 3 Earcaps
Sweet! The cold cast aluminum is what I'll be getting!
Jan 31, 2006, 9:24 AM - Re: MS 3 Earcaps
OH NO YOU DIDN'T ! great idea !
That's ingenius putting plugs into the ear pieces like that. you are sick man, sick sick sick !
Also, suspend me for being stupid, but what is cold casting in metal ? I mean, can you explain the process ?
Jan 31, 2006, 9:29 AM - Re: MS 3 Earcaps
What I find cool... On the 2-piece RF cap, you could replace the plugs with magnets. Everything is already lined up for you!
Jan 31, 2006, 9:44 AM - Re: MS 3 Earcaps
I had to chime in and say that this is extremely awesome!!! Beautiful additions to a mighty fine helmet. Great work as always
Jan 31, 2006, 10:06 AM - Re: MS 3 Earcaps
just out of curiousity if i were interested in just getting the nickel- silver ears how much of a price are we talking?
Jan 31, 2006, 10:59 AM - Re: MS 3 Earcaps
ya thats true. i wanted to get aluminum cast copies of my chest armor so i wouldnt have to keep doing those anoying silver paintjobs that just dont comeout right, but it didnt go far. mabie i can talk to MS & see what he thinks.
Jan 31, 2006, 12:20 PM - Re: MS 3 Earcaps
looks fantastic MS!!!!!!!!!
for the ones that ordered the new stuff... when are you shipping them out? :-)
Jan 31, 2006, 12:24 PM - Re: MS 3 Earcaps
Doh, here I sit with a MS 1 (I think) and find myself drooling over this one as it comes together...ah well practice painting for me eh?
Jan 31, 2006, 12:43 PM - Re: MS 3 Earcaps
What do I use to attach normal earcaps to my helmet? The plugs look a whole lot easier and more straight forward then how ever you're supposed to attach them now
Jan 31, 2006, 12:49 PM - Re: MS 3 Earcaps
You can either use glue (your favorite) or some people use nuts and bolts.
Jan 31, 2006, 1:28 PM - Re: MS 3 Earcaps
On the ROTJ helmet... are the keyholes metal too?
Kind of looks like it in the MOM pics.
Jan 31, 2006, 1:35 PM - Re: MS 3 Earcaps
"IF" they are metal.... then maybe MS could cast those up in the "metal" too. (His scratchbuilt seperate keyholes I mean)
Jan 31, 2006, 1:42 PM - Re: MS 3 Earcaps
That's okay Spidey. You answered the question about the visor edge and that was the important question!
Jan 31, 2006, 3:21 PM - Re: MS 3 Earcaps
Ok your suspended! Cold Casting metal is the process of mixing fine metal powders with an appropriate resin. The pieces generally contain about 1/2 real metal and feel heavy and cold to the touch. Its called cold casting because there is no heat needed to create the reproductions unlike the foundry wax melt off process.
About the armor, I am working on a set still. When its done I'll be able to do a surface coat of the cold cast metal then back it with fiberglass. So you will be able to achieve that metal look/feel if desired.
I doubt the keyholes were metal, but if guys want a CCM copy of my keyhole piece that is completely possible.
ALSO! I wanted to point out that, YES, it would have been way easier just to cast the earcaps right on the helmet, BUT, that is not accurate. The real helmet had seperate earcaps. The system I've come up with is not accurate to the way the movie helmet was designed but it just makes things easier for you guys and a lot more professional in appearance.
Last edited by MARROW SUN; Jan 31, 2006 at 3:34 PM.
Jan 31, 2006, 3:50 PM - Re: MS 3 Earcaps
Will that add a lot of weight to the armor?
Very sweet that this is a possibility!
I like the new attachment method.
The MS3 is coming loaded with a lot of sweet features!
Jan 31, 2006, 6:03 PM - Re: MS 3 Earcaps
wait... you're working on armor too? Woah.:thumbup
Jan 31, 2006, 10:17 PM - Re: MS 3 Earcaps
mmmm.... "metal" armor.
count me in
Jan 31, 2006, 11:30 PM - Re: MS 3 Earcaps
Wait. So how much were the MS3's? And how long will you be making these? I REALLY WANT TO BUY ONE, but I am short on cash, and I probably won't have the money until summer. Will you sill be making them by that time?