Heres my methodology for creating a set of Gauntlets from Wizard of Flight’s templates. Many thanks to Alan for supplying these, but I must note here that the blueprints were not finished when he sent them to me. I hope that someone might get some tips or ideas from this thread.
This is for the Right Gauntlet, the process is the same for both so I’ll keep things simple here.
the first thing I did was create the base which consist of 2x ‘halves’ that clamshell together.
I created a mould from foam board and thin cardboard taking the profile from the blueprints. The foamboard was used as a frame and the cardboard wrapped around to give the shape. The top and bottom are a slightly different shape as you’ll notice once you see the plans. another thing to be aware of is the the sides join at different places (as marked in pencil on the lower left of the next image) so they are not exactly 1/2 round.
Then it was time to get out the 2mm ABS. I cut a piece that would be big enough to wrap around each half, being a bit generous to allow for overlap. After a few minutes in the oven I laid the sheet over the mould and with some gentle pressing I had the base for the right gauntlet. Some trimming was required to get the halves to match up properly, and to add a few details.
To start adding the detail to the top half I first needed to work out what to cut. I did some re-drawing in illustrator and came up with some ‘flattened’ shapes which would eventually shape the top of the gauntlet. These were printed then transferred to ABS and cut out.
The blueprints do not allow for the thickness of material that you use, so bearing that in mind, I had to allow for -2mm where corners met. Some parts have some curvature as well, so clamping while glueing was often necessary. A fair bit of trial and error was also employed when fitting some parts together. The recessed squares detail on the bottom half were simply cut out of the bottom clamshell half, and another sheet of ABS heated and pressed in behind it.
After a lot of filling and sanding (and still much more to go) heres the basic shape for the right gauntlet.
And heres a pic of the parts for both gauntlets.
Hopefully that’s helpful or informative for some of you. Feel free to hit me with any questions.