Page 1 of 2 12 LastLast
Subscribe
  1. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Dec 31, 2006, 2:00 PM - How I put together my Vac Formed Knees #1

    The Styrene for the main body of the knee is 0.080 thick. That is the main section that needs to be able to move and flex. The sides are 0.060 thick. They do not need to move and need to have more detail. So, when I made my new ones, I wanted to make the stronger. I did have some webbing. So I just sanded it down before I started. I also used a heat gun to bend anything else that I did not like into the shape I wanted.

    Here is how my kit started


    Picture of the real thing and our goal of what the kit will look like when done.


    1. I just took a normal pencil and marked a line all the way around. Next, I cut just above that line.



    2. I notched the sides so that they will lay flush with the front of the knee.



    3.Look at the spot in the circle. You will have to trim the bottom of the knee to make this match.


    4. Test Fit. Make sure you sand everything before you glue it together. I mean everything.


    5. I took some extra plastic to go behind to help hold it togher. You will want to make sure that you make this strip as long as you can. I cut this strip to short on my last set and that is where it broke.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	pic01.jpg 
Views:	1491 
Size:	25.9 KB 
ID:	14682   Click image for larger version. 

Name:	pic05.jpg 
Views:	1483 
Size:	29.6 KB 
ID:	14683   Click image for larger version. 

Name:	pic06.jpg 
Views:	1464 
Size:	42.1 KB 
ID:	14684  

    Click image for larger version. 

Name:	pic07.jpg 
Views:	1466 
Size:	31.7 KB 
ID:	14685   Click image for larger version. 

Name:	pic08.jpg 
Views:	1461 
Size:	32.5 KB 
ID:	14686   Click image for larger version. 

Name:	pic09.jpg 
Views:	1454 
Size:	44.0 KB 
ID:	14687  

    Click image for larger version. 

Name:	pic10.jpg 
Views:	1317 
Size:	33.5 KB 
ID:	14688   Click image for larger version. 

Name:	pic04.jpg 
Views:	1464 
Size:	42.3 KB 
ID:	14689  
    Last edited by asok; Feb 11, 2008 at 9:02 AM.
  2. Skalen Fehl's Avatar
    Member Since
    Dec 2003
    Posts
    789
    Dec 31, 2006, 3:35 PM - Re: How I put together my Vac Formed Knees #2

    Nice! Is it flexible? I've always been worried about breaking my fiberglass knees from bending my knees to far or too quickly.
  3. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Dec 31, 2006, 3:42 PM - Re: How I put together my Vac Formed Knees #3

    Seeing that I have not had time to totally finish them I am not sure. I know that my current ones that are .060 will flex. I just did to many photos on one knee with kids. Oh well.
  4. I helped at SDCC '08 GCNgamer128's Avatar
    Member Since
    Jan 2006
    Posts
    5,520
    Dec 31, 2006, 7:09 PM - Re: How I put together my Vac Formed Knees #4

    Those look great for being vacuuformed!!
  5. I helped at SDCC '08 The Clayster's Avatar
    Member Since
    Aug 2006
    Posts
    1,586
    Dec 31, 2006, 7:52 PM - Re: How I put together my Vac Formed Knees #5

    awesome
  6. superjedi's Avatar
    Member Since
    Jul 2003
    Posts
    4,383
    Dec 31, 2006, 8:22 PM - Re: How I put together my Vac Formed Knees #6

    Quote Skalen Fehl said: View Post
    Nice! Is it flexible? I've always been worried about breaking my fiberglass knees from bending my knees to far or too quickly.
    I have vac-formed Boba knees similar in construction to these. I reinforced the joints with JB Weld and it would probably take a nuclear bomb to break 'em now.
  7. Bluewolf's Avatar
    Member Since
    Feb 2006
    Posts
    111
    Feb 8, 2007, 8:28 PM - Re: How I put together my Vac Formed Knees #7

    Where did you get your knees? My JD knees were tacky when I got them over 6 months ago, and the gel coat still hasn't fully cured. Short of finding a way to cure them, I could use a new set of knees.
  8. Wildabeast's Avatar
    Member Since
    Jan 2007
    Posts
    547
    Feb 8, 2007, 8:37 PM - Re: How I put together my Vac Formed Knees #8

    cool knees.....but how do you atach them to the suit...??
  9. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Feb 25, 2007, 12:35 PM - Re: How I put together my Vac Formed Knees #9

    Quote Wildabeast said: View Post
    cool knees.....but how do you atach them to the suit...??
    Put velcro behind the main section of the knee and snaps on the left and right side.
  10. The Sniffer is offline The Sniffer
    Feb 28, 2007, 9:39 PM - Re: How I put together my Vac Formed Knees #10

    asok. You are one talented man!
  11. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Mar 11, 2007, 3:21 PM - Re: How I put together my Vac Formed Knees #11

    I updated the pics and there will be updates as I finish mine.
    Last edited by asok; Mar 11, 2007 at 3:26 PM.
  12. Apr 10, 2007, 2:58 PM - Re: How I put together my Vac Formed Knees #12

    Count me in for a set with knee darts as soon as you have a set ready for shipping.

    Please PM for details on S&H, and paypal info.

    Thanks

    Those look great!

    DM
  13. bobafett669's Avatar
    Member Since
    Jun 2004
    Posts
    988
    Apr 12, 2007, 6:10 PM - Re: How I put together my Vac Formed Knees #13

    nice work Sir!!!
  14. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Aug 5, 2007, 5:08 PM - Re: How I put together my Vac Formed Knees #14

    I have found that with vac pulled knees they last a long time. They just don't have that much detail. Fiberglass has great detail, but they break to quickly. So, I am trying to get the best of both worlds.

    I have found that the main body of the knee needs to be able to move and bend. So, making it out of 0.080 styrene works great. The sides do not need to flex and that is where we need the detail. So, here goes. I had some soft pulls to test on so, they are my test parts.

    The side with the upside down "F" is cast in the same resin that just the "F"s where cast in. So, I put them together and made a new mold. Now you heat up the "tail" and use a clamp to hold it in place while it cools. Then just glue it in.

    I have not found a way that I like to make the side with the darts in fiberglass. I can be done, I just don't like the way they come out. So, I am going to pull them out of 0.060 styrene to get better detail and not compromise strength.

    What do you think?
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	TheF.jpg 
Views:	395 
Size:	31.9 KB 
ID:	19315   Click image for larger version. 

Name:	TheF01.jpg 
Views:	391 
Size:	34.8 KB 
ID:	19316  
  15. I helped at SDCC '08 MandalorFett's Avatar
    Member Since
    Nov 2005
    Posts
    2,738
    Aug 5, 2007, 7:53 PM - Re: How I put together my Vac Formed Knees #15

    I like it. As an owner of your knee armor, I think the one piece side with tab will increase ease of use and overall strenth to the build up. It looks nice and neat , and it cuts out "variables" that comes with fitting more pieces together.
    Last edited by MandalorFett; Nov 28, 2007 at 10:46 PM.
  16. FettFanatic's Avatar
    Member Since
    Aug 2006
    Posts
    749
    Aug 7, 2007, 9:48 PM - Re: How I put together my Vac Formed Knees #16

    I like what you are doing with the kit. I wish there was a way to make the whole thing out of one type of material for ease of production and assembly. Is there any way to reinforce fiberglass so that it wouldn't crack as easily? I thought maybe a layer of the metal window screen mesh embedded in the topcoats would add strength and would be thin enough to work with. What do you think?
  17. JDFett's Avatar
    Member Since
    Aug 2005
    Posts
    998
    Nov 27, 2007, 11:48 PM - Re: How I put together my Vac Formed Knees #17

    i will tell you this...i have his kit and it was all styrene and i love them...easy to put together and they look great. I added some aluminum knee darts to mine and they really look great
  18. TK0363's Avatar
    Member Since
    Jul 2007
    Posts
    83
    Nov 28, 2007, 4:09 AM - Re: How I put together my Vac Formed Knees #18

    Are these still available?
  19. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Nov 28, 2007, 9:48 PM - Re: How I put together my Vac Formed Knees #19

    Thanks JDFett. I got my darts from Dark-Side and they look great.

    TK0363, you have a PM.
  20. Z-man12's Avatar
    Member Since
    May 2007
    Posts
    224
    Nov 29, 2007, 12:15 AM - Re: How I put together my Vac Formed Knees #20

    Can you send me a pm with details too? I might be intrested.
  21. JDFett's Avatar
    Member Since
    Aug 2005
    Posts
    998
    Nov 29, 2007, 2:13 AM - Re: How I put together my Vac Formed Knees #21

    if you click on my website in my signature there are a few shots of my asok knees and the construction in the jango page
  22. TK0363's Avatar
    Member Since
    Jul 2007
    Posts
    83
    Nov 29, 2007, 6:12 AM - Re: How I put together my Vac Formed Knees #22

    Thanks asok, PM back to you.


    Tony
  23. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Nov 29, 2007, 9:18 PM - Re: How I put together my Vac Formed Knees #23

    Tony got my last set of knees. I will try and do another run in the spring.
  24. ItsThatGuy's Avatar
    Member Since
    Mar 2007
    Posts
    1,056
    Nov 29, 2007, 9:28 PM - Re: How I put together my Vac Formed Knees #24

    Quote asok said: View Post
    Tony got my last set of knees. I will try and do another run in the spring.
    I did...?

  25. asok's Avatar
    Member Since
    Dec 2002
    Posts
    2,707
    Nov 29, 2007, 9:41 PM - Re: How I put together my Vac Formed Knees #25

    You a funny guy! Where is your stage and mic?

Similar Threads

  1. Difference between ESB knees and ROTJ knees?
    By Studio Fett in forum Boba Fett Costume
    Replies: 0
    Last Post: Jan 26, 2009, 11:55 AM
  2. Anyone ever done a vac-Formed Helmet?
    By hellopike in forum Boba Fett Helmet
    Replies: 64
    Last Post: Sep 1, 2007, 2:37 AM
  3. finished a pair of vac-formed knees/comparison
    By Jango 5204 in forum Jango Fett Costume
    Replies: 7
    Last Post: Feb 20, 2007, 7:30 PM
  4. Vac-formed Helmet
    By Jodo_Kast in forum Boba Fett Helmet
    Replies: 10
    Last Post: Mar 30, 2006, 5:44 PM