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  1. MonCal's Avatar
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    Jan 28, 2005, 12:22 AM - Armor progress #1

    I Sculpted up the chest armor tonight yay!!!!!!

    It wasn't as bad as I thought it would be.

    .











    I will mold it up and make these in fiberglass and vac-form the top (silver) piece. It will be a breeze to lightly sand the fiberglass to get it more smooth. Since this piece is covered in leather, it should work pretty slick.
  2. Mr Fett's Avatar
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    Jan 28, 2005, 12:28 AM - Re: Armor progress #2

    Wow, that looks really nice. You've got some excellent pieces you've made, MonCal. Your collection of parts grows......


  3. MonCal's Avatar
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    Jan 28, 2005, 1:13 AM - Re: Armor progress #3

    Thanks!!!

    We'll get this costume done one of these days

    I think I'll start on the hand guards next

    Gotta get some silicone first though.
  4. Admin Staff MaulMaus's Avatar
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    Jan 28, 2005, 8:42 AM - Re: Armor progress #4

    Y'know MonCal ... I'm beginning to think you're a professional Zam costume maker! You're putting the rest of us (okay... maybe just me!) to shame!
  5. judz dwedd's Avatar
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    Jan 28, 2005, 9:15 AM - Re: Armor progress #5

    Hey MonCal, I just finished the handplates. If you want, I could cast you a set, and save you the trouble of making them. I'll be working on finishing those gauntlets next.
  6. Mr Fett's Avatar
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    Jan 28, 2005, 9:20 AM - Re: Armor progress #6

    MonCal AND judz dwedd......looks like we'll be coming to you in the future whenever we get around to finishing off Kimmy's Zam costume.
  7. SEEKER's Avatar
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    Jan 28, 2005, 10:14 AM - Re: Armor progress #7

    you guys kick butt
  8. MonCal's Avatar
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    Jan 28, 2005, 8:38 PM - Re: Armor progress #8

    Judz,
    SWEET!! maybe we can work a trade
  9. judz dwedd's Avatar
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    Jan 29, 2005, 6:32 PM - Re: Armor progress #9

    Ok, what do you propose?
  10. MonCal's Avatar
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    Feb 1, 2005, 1:47 AM - Re: Armor progress #10

    Quote judz dwedd said:
    Ok, what do you propose?

    Hmmm, I'll have to see what I have that you want I'll have to think a little on that one.

    Do you have pics of your progress on the gauntlets and such so far?

    I finished my mold of the armor and mixed some fiberglass tonight..... still loopy from the fumes
  11. MonCal's Avatar
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    Feb 3, 2005, 4:48 PM - Re: Armor progress #11

    Fresh out of the mold:



    And trimmed:



    I have to make a mold of the inner section that I can vacuum form the top piece from so it'll be a few days....
  12. Admin Staff MaulMaus's Avatar
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    Feb 3, 2005, 5:43 PM - Re: Armor progress #12

    Wow! Like I said... a professional Zam Costumer!
  13. Mr Fett's Avatar
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    Feb 4, 2005, 12:29 AM - Re: Armor progress #13

    I love it! You rock!
  14. judz dwedd's Avatar
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    Feb 4, 2005, 8:04 AM - Re: Armor progress #14

    Looking very good. I also like the center piece, you're holding up to your sculpt. Did you make that, as well?
  15. MonCal's Avatar
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    Feb 4, 2005, 6:41 PM - Re: Armor progress #15

    Thanks guys.

    The hose connector piece was made by ZamIAm. She did the whole set of greeblies and they are awesome!

    So Judz, will you be needing some armor?

    I'm still working on the vacuum form molds so give me a few days and I'll have some more updates
  16. BobaBabe's Avatar
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    Feb 6, 2005, 10:11 PM - Re: Armor progress #16

    Mon, it's beautiful. What fantastic work. I'm just trying to understand how your brain understood the measurements to make it life size! Woot! Maybe one day I'll be as cool as MonCal and be casting that well!
  17. BobaBabe's Avatar
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    Feb 6, 2005, 10:55 PM - Re: Armor progress #17

    Wrong Post! ACK!
  18. judz dwedd's Avatar
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    Feb 7, 2005, 9:14 AM - Re: Armor progress #18

    Quote MonCal said:

    So Judz, will you be needing some armor?

    Absolutly !

    What do you think about casting the gauntlets out of that flexible urethane you use for your shins? Then, they would need only one split to put them on.
  19. MonCal's Avatar
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    Feb 7, 2005, 8:24 PM - Re: Armor progress #19

    Hmmm,

    Possibly. I'll give it some thought. The only time I've put a finish on that plastic is on the toe spikes. They were primered, silver misted, flat black misted, and rub n buff on top. They seem to be holding the finish fine so the gauntlets would probably be fine too. What do ya think?
  20. judz dwedd's Avatar
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    Feb 8, 2005, 8:27 AM - Re: Armor progress #20

    I think it's worth a shot. Can you give me the name of it, so I can order some? If it doesn't work, I'll just run them in fiberglass.
  21. MonCal's Avatar
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    Feb 8, 2005, 5:47 PM - Re: Armor progress #21

    It's from smooth-on.com . The plastic is: C-1509 semi rigid casting resin.

    It takes about 3 hours for it to set up and then about 16 hours before you can pull it out of the mold. If you can rig up some sort of roto-caster, you can get it to do a hollow shell. I could probably modify a mold to fit in the roto-caster I made for the shins:



    I've since put a motor on it so I don't have to rotate it by hand for 3 hours
  22. judz dwedd's Avatar
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    Feb 8, 2005, 5:56 PM - Re: Armor progress #22

    Maybe I could rig the mold in my lathe, and spin it for 3 hrs on low speed.
  23. judz dwedd's Avatar
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    Feb 8, 2005, 6:09 PM - Re: Armor progress #23

    Smoothcast 60D has the same shore hardness, and only has a 3 minute pot life/10 minute demold. I could rotocast that by hand.
  24. sithlord23's Avatar
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    Feb 8, 2005, 6:10 PM - Re: Armor progress #24

    Man, that is looking awesome! can't wait to see more!
  25. MonCal's Avatar
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    Feb 8, 2005, 9:54 PM - Re: Armor progress #25

    Thanks sithlord!!!


    Judz, that might work. I haven't used the smooth cast 60. I've used the 10 and the 25. You might want to email them and see if it is similiar to the 1509 or at least do what you want it to do.

    I just finished pouring the last hydrocal piece that I will use for vacuum forming the top / silver plates on the armor.

    Here is a little of the process :

    ** I built a clay wall around the fiberglass I made earlier:


    ** This is the hydrocal piece I poured over the fiberglass:


    ** Then build another clay wall around that hydrocal piece and grease it up with vaseline to pour more hydrocal on top of that:


    ** Then I have a positive hydrocal piece to vacuumform off of. It's still fresh so I need to wait a day and then do some sanding and clean up:

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