Cardboard Gauntlets WIP

I just got started a few hours ago, and I already have all the pieces together on the right one. By-the-way, the rectangular piece on top in the top picture is not crooked, it is the shadow making it look that way.

I don't have pics of the lower clamshell portion, because glue is drying.

I plan on using wallboard joint compound to make the corners more rounded like the screen used version. I am not planning on spending any money building or painting these, so I will have to scrounge for hoses and other greeblies...I think nobody will notice if I snag the one from the refrigerator.

I'm making mine from cardboard too. I'm just using spackling to basically cover the outside and then sand it down to make it the connected look of the vac formed ones.

Yours looks awesome! Keep up the good work!

Here is my hinge. It is a strip of cardboard that has been cut 1/4 of the way thru, straight down the center of the strip, and folded back and forth on itself while wet. Now that it is dry, there is a v-shaped gap on both sides that is almost as strong as the original cardboard was. It has been glued down with white glue on the flat surfaces, and hot glue on the edges to keep it flush with the edge of the cardboard. I haven't decided what to do to secure it once it is closed.

Very Nice work guys....
I tried card but failed miserably...
Keep us posted

Looks great -

Q: What type of cardboard are you using - name brand - thickness - where did you find it ???


Q: After assembly of the major parts - do you think that one can apply fiberglass/resin mix over everything - inside and out - and make the whole unit very strong? ( Or even contact cement )

Originally Posted by TK1799jhw

Looks great -

Q: What type of cardboard are you using - name brand - thickness - where did you find it ???


Q: After assembly of the major parts - do you think that one can apply fiberglass/resin mix over everything - inside and out - and make the whole unit very strong? ( Or even contact cement )

The cardboard is from a desk calendar approx. 18x24" the brand is Brownline it is about 1.5 mm thick. I got a stack of them from an office supply store. They were free because they were last years calendars.

Yes, you can cover the cardboard with fiberglass resin. I would seal it first with an acrylic seal beforehand, so the cardboard doesn't warp once wet.

You are a master!

I take it - you used the templates (posted on TDH) or pretty much made up your own?

Have you found them to be accurate?

Thanks for the info -- I have Sintra in my shop - but it's 1/8 inch thick and when heating it warps a bit -- I believe the 1mm is easier to work with as seen on TDH by another member. But the cardboard is very interesting...

I am using the templates provided by Wizardofflight and Mojofett. They are the masters. The corners need to be rounded like the originals, but other than that, they seem to be spot-on. Getting the corners rounded is pretty simple, so there is not much work going into it on my end.

that is sweet!

Nice scratch build there DB...

I've got the first layer of wallboard joint compound on the right one, and while I am letting it dry, I started the left gauntlet.



Eeew! It's all messy!







I've got to get a better camera.

From the looks of things, I should be ready for paint by Monday.

Great idea with the elastic!!!!! I never really thought of that. Too bad I already bought hinges. I guess I could return them.

I'm using spackling to round corners and such, what are you using brand-wise?

Originally Posted by Kashyyyk4ABY

Great idea with the elastic!!!!! I never really thought of that. Too bad I already bought hinges. I guess I could return them.

I'm using spackling to round corners and such, what are you using brand-wise?

I am using DAP brand wallboard joint compound. It was left in the house I just moved into...I have 5 gallons of it, I've gotta use it for something!

Keep the hinges, they will last longer. The elastic on mine will eventually pull the glue off of the cardboard.

What kind of spackling are you using?

I'm using DAP Drydex Spackling on mine, it sands really well, I've been using it on all my pieces. I swear I've gone through 3 tubs of it.

I may have to redo my gauntlets, the cardboard is too flexible. The next ones, I will just cover in fiberglass resin. I will wait and see if the joint compound makes it stiffer, or just crumbles. Only time will tell.

As I was typing this, I just realized that I have about a dozen cardboard newsprint spools that would be perfect for the base of the clamshells. They are super stiff and stronger than the pvc pipe that I used on my jp.

Primer...


The corners aren't quite as sharp as the picture shows, but they aren't as rounded as I would like, but that's all I could get without losing detail.

I have the other one primed (upper part only), but it is drying at the moment, so I will have pics later. The reason I don't have the lower part done, is because It came out too small to fit my arm. I checked the printer, and it wasn't the problem, maybe my left arm is bigger or something? Weird... Anyway, I am still working out the right size, so It will be assembled after I get the right one painted.

Dude - you are a genius!

I started mine today - cut the right gauntlet out and with cyno-glue - was able to piece everything together. I'm using contact cement right now to coat the pieces (on both sides) - then I plan on moving to a fiberglass coat that will hopefully finish it off.

Sand - paint - and done. That's the plan anyways. What you have done so far if outstanding -- I got real excited when I read this post and kept going over it in my head. Now that I've started - I hope everything will pan out correctly.

Thanks for the info and leading the way in this project...

Catch my stuff I've completed so far here: http://www.thedentedhelmet.com/f34/desert-mandalorian-warrior-j-fenn-20544/

What do you think --?

love the jet pack!

*** Db, this is incredible.

Once again showing people like me that there is no problem that cannot be overcome (or no prop that cannot be built) with the right mixture of ingenuity and Bondo.

I haven't done any more work on the gauntlets, because I am currently working on a flat pattern for the gauntlet missile. When I am finished, I will post a new thread with the download link. The missile will be made of cardboard also. I should have the pattern done in a few days.

OK, I lied... I put some paint on it an stuffed some pieces of a broken plastic hanger in it for the pipe thingys leading to the hoses. the top hose connector is a pencil.



By-the-way, if anybody wants my cardboard helmet and gauntlets after Halloween, I was planning on giving them away. They are by no means accurate, but most people won't notice. I can pay for shipping(U.S. only, if you are from abroad we can discuss options), just email me at dung_beetle_@hotmail.com and let me know if you want just the bucket, or whatever. If nobody wants them, I will just give them to some random kid.

That's fantastic work!

I'll take 'em, the helmet and the gauntlets.

I know of a big kid who'd flip over them. Boba's his second favorite after Vader.

Send me an email after halloween, and they are yours. I might be getting rid of my trashcan armor as well.

Forgot to show the left one...



The nozzles on the flamethrower are rings from a couple of hairbrushes. I'll be making the calc pad, buttons, and switches from cardboard also. I have made the hose hardware out of cardboard, and will see if they are strong enough to hold the hoses while wearing them.

I still have a lot of work to do on them, but I prolly wont get to it for a while. I am currently working on the flat pattern for the gauntlet missile. I also have to get started on my son's jawa costume as well.

Excellent work DB.... can't belive they are made from card!!

Will do. I'm poised on the keypad until after Halloween.

Originally Posted by dung0beetle

Send me an email after halloween, and they are yours. I might be getting rid of my trashcan armor as well.