My Zam Project Progress

Im liking that neoprene a lot! Good progress guys - keep up the good work!

Looking great guys!

Wow! You've certainly put a lot of work into it! Great job! Keep those progress pics coming!

Sweet!! You're making some good progress. This costume certainly isn't an easy one. I'd rank it right up there among the most difficult! .... don't let that statement overwhelm you though ... just plug away one piece at a time

Wow - you are making tons of progress! Great job

Wow, good for you! Doing all the clay greeblies yourself!

so i finished my greeblies...molded and casted and im very happy!



(if anyone is interested in a set...ive got a thread in the cargo hold as i have enough to pour about 6 more sets)

we also got our boots today...here is a mock up with Moncal's(the wizard of zam as i like to call him) shins and boot parts!...now to finish those up!

Wow, you've done an amazing job!

Awesome! Now I can't wait until I get my wifes boots done to get those shin and toe peices!

Lookin' good!

Lookin good!!!

Say.. what type of hose are you using? It looks pretty good and it appears to be more flexible than the stuff I have. Dallas found some stuff at one point that was pretty good. I think it was some sort of dive hose but I don't remember for sure.

actually beleive it or not it's from my wife's work...she works at a hospital and its from a respirator type hook up...funny that it's real hose for an oxygen supply.. it does have good flex and is the right size but we were not sure if we liked the coil size...seems zam's is a bit more spaced out so we are still kind of looking...this hose we have may be good for the helmet back though

Wow! You must be pleased. Some great work there dude

ya..very happy so far with the progress..but man is it a long haul doing this costume...ive got a vader, EP3 clone, maul and biker and it didnt take me as long as this one is...its more the funding and the extra scratch work thats really the tough part...not to mention im kind of a instant gratification kind of guy so this is a new road for me to travel...but its also very rewarding when you find the right thing that works for you and you can see stuff starting to come together...I can't wait to see my honey in this!

Yeah... I hear you! This is definately one of the most challenging costumes out there! I've got a friend who's redone a Maul and a TK, made a Vader a Jack Sparrow and one other (I forget) in the time I've been plodding along on my Zam... then asks my why I'm not done yet? ... Erm... because it's HARD!!! I would've given up long ago if it weren't for ZIA, MonCal and DCB! :thumbup Thanks guys and gals! *grabs tissue*

I can't wait to get this done... and finally have something to show for all the work!

thanks for the info...she actually used the reference cd for hers and tried to simulate the corrosion patterns to the best she could tell in the pictures...went with a more metallic and darker color because most pictures flash out the true color. i think it looks great and think she is on the right track...

Yeah i agree with what youre saying, mine are matched to the flash picures so look quite bright so to blend them a bit im going to dirty them down a little. Its hard to know what to go with.

I painted my dagger with Games Workshop paints and acrylics from the craft store. Where you and Zia have used brown i have used dark orange stippled with a dry brush over a blue.

Mine are quite bright.

Another little thing i noticed im no sure if im correct but the safety on your little blaster i think is black not silver. Did you rember what silver paint you used on that tho as it looks really good

actually the silver on the blaster was a pain..we used a aluminum paint..i ight suggest using rub and buff on anything you are looking to make "metal"...the aluminum and chrome (any matallic paint actually) is very thin and runs easily and can really be a chore to use...as far as it being silver(the safety) not sure..lemmie check the disk....

(pause)

couldnt find a reference shot on all my pictures...she is always holding the blaster so the safety is away from view...so not sure...i say go with what makes you feel good on that one unless someone has an actual shot of that side of the screen used blaster? i just thought it was too cool to go un-noticed

also messed with the color and photo's contrast above on the greeblie to make it look more like it does in person...

I think I must've repainted my greeblies 3 times.... then I dirtied them up, because they were so bright. Still not happy with one of them.

I ended up using Rub-n-Buff on my resin blaster as well. I like it much better - it looks more like the real thing. Paint just doesn't look the same. The safety on both my blasters is black (resin and aluminum). Though, I think it kinda looks cool being silver!

I don't have the references like you folks do, but I have a pretty good eye for detail...

Any idea what the silver thing is on the right side of the blaster barrel? I was thinking it was the safety, but its too high.


Hope this helps!

*points blaster at self* Arrgghh!!! I think it's just the way the light is hitting the left side of the blaster, because that whole bottom section is black. And the only thing sticking out below the barrel is the black thing that holds the barrel.

Originally Posted by MaulMaus

*points blaster at self* Arrgghh!!! I think it's just the way the light is hitting the left side of the blaster, because that whole bottom section is black. And the only thing sticking out below the barrel is the black thing that holds the barrel.

Yeah I was thinking it was the bottom too, but wasn't sure why it was silver. I never thought about lighting...makes perfect since though.

Originally Posted by sl/tk8456

Becky's are bright and look like a talented child has painted them.

well for the universal key we went with the concept that the original pieces was all copper and the other colores were various levels of patina from being old...we actually sprayed a couple coats of flat matte clear to it since the picture and it does look less bright and shiney now

I have done my greebs now i posted them in my progress thread. I think everyone is going to have different colors. im happy with mine but i need to see how they look on the costume as a whole not just on their own

so we wanted to see how things were coming together...we did a quick mock up of the armor, using our carboard template(havnt made the leather piece yet)...i think everything looks good together...a couple small issues with some of our parts but thats why upgrades are a never ending battle...should look nice together when it's done....

Lookin good!

Lookin' amazing. I can't believe how quickly you've gotten so far!

Great work. When that ab assembly is completed it looks way cool

we went out to tandy leather today and got some scraps for the ab plate and the trim on the armor...
here is what we came up with after finishing the ab plate



we are going a bit darker(our preference as we are trying to mimic the on screen zam more than the actual color suit used) but i think it came out great...we even curled up the left bottom corner and put the wear marks in it...used purple and red dye, toned down with some rubbing alcohol...then used mahogany antiquing for the darker (weathered) spots

Very cool! Good to see it's coming along!

BTW - did you come up with the template on your own, or was it blown up from the visual dictionary images?

actually i just freehanded it from the book onto a piece of cardboard..then referenced it off the other armor i got form cal and the greeblies...making sure it matched what i saw in the dressing the galaxy book..it is a tad dark but im going for the darker color for the leather..i like the more weathered look...

having trouble with the vest though...we tried a mock version with some cheap pigskin today and we tried it pattern-less it was okay but i got a bit stumped on some of the areas cause ive never done anything like that before..i guess ill pick up a vest pattern

Originally Posted by JDFett

having trouble with the vest though...we tried a mock version with some cheap pigskin today and we tried it pattern-less it was okay but i got a bit stumped on some of the areas cause ive never done anything like that before..i guess ill pick up a vest pattern

Um... Yeah... might be a good idea!!! ... Lesson #1 ....

There's a thread on the Zam boards here to a leather vest pattern I found that works very well, with some alterations. A regular vest pattern would also work, but will require more alterations - just keep that in mind when you make your pattern. Also, it's always a good idea to make a muslin mock-up of your piece before cutting up your leather (or expensive fabric ) so you can check for fit and/or cutting and sewing issues ... but if you just want to wing it...

i think to be honest..the hardest part of this entire costume is going to be the vest and the belt...ive been looking around for a reliable leatherworker to do them for me but even some of the better folks are afraid to tackle it(maybe my instruction on it being so presice is scaring everyone.. ) what was the consensus on the size for the eyelets?

I was looking for some sort of tutorial for the vest and belt on the thread and there really isnt much...any help on the belt construction would be appreciated

As Yoda would say... "Look through the threads you must!" Do a search - there is at least one thread with good information on the vest and one on the cummerbund/cumberbund (spelling???) here on the boards with links and/or information on how to make the cumberbund here.

The vest isn't so hard really, if you've got some basic sewing skills. The cumberbund is pretty basic as well.. Maybe it's the dyeing/coloring the leather that has you so nervous?

Ill also be looking for the same threads in a second. I have my eyelets, ive measured them and the are supposedly the correct size but i dunno they just look small Right im off to use the search thingy ma doodle!

Originally Posted by Langsuir666

Ill also be looking for the same threads in a second. I have my eyelets, ive measured them and the are supposedly the correct size but i dunno they just look small Right im off to use the search thingy ma doodle!

Can you post a pic of the eyelets next to a measuring tape/ruler? Before you go poking holes in your vest? Those things are a pain in the you-know-what to get out! I'm also sending you a PM!

JDFett: Yes... but the answers you seek are in the threads... Honestly, I just printed the things out because I kept having to refer back to them over and over and over. (If you can save to a PDF File, then you can just print the page(s) you need w/o wasting a lot of paper). The answers aren't straight forward and simple.... there are also links and measurements, etc. on those threads ....

so true...good idea as well

so I've been working on Jamie's vest...we decided to go with a really cheap pigskin for a test run...($18 bucks total!)

the pictures show the final fitting for the test...I will be using the test vest as our pattern for the actual one. the pictures show some comments as well....





actually didnt use a pattern for this test...kinda modified my biker vest ive got a tad to get the general jist of the vest

I thought the vest was supposed to have a plunging neck line?

Lookin' good so far for a rough draft!

in response maulmaus...the only reaosn we didnt put in the epulets is because those are really not anything needed for the actual pattern...after i get the other vest done to this point i will most likey do a dry test on this for those pieces before doing the final vest. also with the zipper i actually pined it extra tight in the front to allow a little leeway without wasting a zipper and time on this test vest(hey that rhymes )

ya, with the darting, it does need to be higher...but ill wait to make the adjustment on the actual vest as thats just a matter of making a cut adjustment on the other material...I also used a black sharpie to mark all the way around the hem so i know where exactly to cut the other material(adding the extra sewing area of course).

I think that the onyl way to get the correct looking curved hem is by doing the inside out method....once done anything can be turned right side and as long as you stitched it along the line youll end up with a real nice finished edge...plus her vest just seems to have more weight to it than one ply (2 oz) pigskin.

most definatley try out the color first on scrap before the final spraying....you got that right!


Tony, is there even a picture of the front of her vest showing that type of neckline? I assumed you would need it high so you could attach the armor with some clips


thanks for the input...thats what it's all about

Originally Posted by MaulMaus

ItsThatGuy: Plunging Neckline??? Uh...No...

Originally Posted by JDFett

Tony, is there even a picture of the front of her vest showing that type of neckline? I assumed you would need it high so you could attach the armor with some clips

::shrugs:: thought I read that some where....guess not...

Wow! Our seamstress offered to do this for an estimate of £50 which i think is very reasonable. I would be happy to pay up to £100 for it to be done right rather than me mess it up LOL

as you know Jamie and i went out to a seamstress today to see if she could do the undersuit...she said she could for like 500 bucks! NOT IN THIS LIFETIME I figure I can sew, albeit not as well as a professional, but enough to decide it wasnt worth 500 clams right now!

so we went out looking for a pattern we could revamp and picked up this


we figured it would help with a few areas like sleeves and crotches

i went to work on this while jamie was out at her moms and got both legs together...just need a final fit on Jamie..hoping to get them done tomorrow...they are not perfect by no means but they look pretty good..

here you can see the raised stitching on the center of the side of the leg

then here i was reusing the pattern to cut out material for the saddle part

this is a close up of the two pant legs...just need tailor them so they are tight on Jamie and sew them together...

and i long view of both finished pants panels

Very cool! I'm glad you can sew! We have a great tailor within a mile of our house, they did Aimee's Jawa for $120 - but that was a higher rate because we needed it rushed. Also all we had were reference shots, no pattern. They went above and beyond!

BTW - how did you end up doing the seams? Can you show a close up of the in and out side so I can use as a reference later?

There is only a single welt seam on the arms as well as the legs ... you can see it on some of the pics (like at the NY FIDM pics that were posted elsewhere on the forum here ). It just looks like more "seams" on the pic above because the fabric is shiny, the thickness of the fabric and the angle the picture was taken at. The leg "saddle" seam looks smaller because of the way it was sewn. (It may also be just a second layer of the lycra sewn onto the regular neoprene/lycra material).

So, there is a single welt seam on the outside seam of the arms. A single welt seam on the outside of the legs and the welt seam for the "saddle" seams on both the legs. The rest of the seams are regular seams. (Please, if I'm wrong, someone correct me!).

Ooooh i thought it was a double welt - ack :s So just a single welt or less all over, no double welt anywhere?

*Ack!!!* Better double check my sewing terms here!

Okay According to my Vogue Sewing bible/book: (Paraphrased)

A welt seam (Single Welt Seam) Is a regular seam, with the seam allowance pressed to one side. You trim the lower seam allowance then you then stitch again parallel to the first seam, encasing the lower seam allowance. So what you see is only one row of stitching parallel to your first seam.

A Double Welt Seam - You complete the regular welt seam as above, then topstich close to the first seam you completed. It looks similar to a flat-fell seam (Like on jeans) and you see two rows of parallel stitching.

After looking at the pictures from FIDM and from DCB's Reference CD - I think all the welt seams are Single welt seams. I don't see any second row of stitching at all. That would also explain why all these seams are more rounded, rather than flattened.

Oh dear, my seamstress had a look at the pics and i think she sewed us a double welt on a test piece. I really thought the leg saddle type piece seams were double, i better have a close look at the ref CD!

well to be honest...i tried a single welt seam on the saddle part and it was a nightmare trying to get it right, so i went with a double so i could get the nice straight stitch lines on the turn...i also did a single welt seam on the leg and will do the same on the arm, but i also stitch the other side becuase to me it looks better...so im not totally exact...not worried...

so while on a sewing break, I thought id finish up jamie's chest armor that ive been working on...here it is finished...I took the shot with the DTG picture in the background so you can see i tried to mimic the actual piece the best i could(no i didnt go fett crazy on it!) Used silver leaf, then detailed it with some spanish copper and some pewter, all R&B stuff

Originally Posted by JDFett

Originally Posted by Langsuir666

Oh dear, my seamstress had a look at the pics and i think she sewed us a double welt on a test piece. I really thought the leg saddle type piece seams were double, i better have a close look at the ref CD!

I wouldn't worry about it! Honestly... It is so hard to tell, especially in some of the pics (and I could be wrong ) I think you have to go with what works in the situation (if the seam is sticking up funny - well, you may need to stitch it down! ) I'm sure your suit is gonna look fabulous if it has single or double welted seams on it! At least you're gonna have a suit!

JDFett - Chest armor looks great! I have half of my lettering cut out ... taking longer than I thought to get that part done!

thanks maulmaus!

and we finished her pants tonight as well....except for the hem by the ankle and the waist...i need to buy some draw string for her waist before i hem it....
(doubt thats canon either but it will help keep her pants up )

Lookin' good! Lookin' real good! :thumbup

How'd you manage to cut out those letters?

real slow with a razor knife...took about an hour to do it...wasnt easy

:o If you notice you and I posted pretty much at the same time. I never saw the pants until just now!

Man, I wish I could sew! Great job on that too!

So how much you got left on your Zam? Looks like it's really coming along fast!

An hour!!! What's my problem ?? I've been using a hot craft knife - has an x-acto on the end - I spent what... 2 hours or more just on the one side.... I swear it takes me 2x or 3x longer to do everything than it takes everyone else... ... Oh well...

It took us AGES, and we messed it up lots and slipped LOL - well I messed it up lots and slipped then John fixed it haha!

I love your chest pieces there, very accurate!!! Body suit looks like its comming along real nice! Awesome job youre doing!!!!! You will be finished before us!

Yeah MM the seams i think youre right on the legs they are single and that line does look likje a shadow on the arm im just sure i remebered Zam I am saing she used double on the arms somewhere maybe im wrong hehe

well there is still a tone of work as you know...top, skirt, finish vest, gaunlets, helmet assembly, new aluminum balster assembly, belt, cape, viel, boot assembly.....argggg!!! , plus Jamie need to finish painting the rest of her greebs...here is the cape seal she finished yesterday



as far as the seams...the ones down the leg lenght and the arm length i would say most def single...if the ones on the saddle are single...i have no clue how they did it because its near impossible to make such a perfect corner by the knee without doing a double...thats how i did it after trying the single three times and saying...forget that!

so Jamie also worked on her boots too...here's a quick mock up...we painted them with my old anakin nulife color...i think we will be redoing them with a more milk chocolate color...she still needs to do the weathering on these pieces...



i also found a fairly accurate pair of leather gloves at the local department store(agway)...surprised that they looked so close...just need some purple

JD - what's that book underneath the gloves?

BTW Everything is looking great!

Edit: Also, do you have a item number for those gloves? I'm still looking around for a nice pair.

Originally Posted by MaulMaus

An hour!!! What's my problem ?? I've been using a hot craft knife - has an x-acto on the end - I spent what... 2 hours or more just on the one side.... I swear it takes me 2x or 3x longer to do everything than it takes everyone else... ... Oh well...

this is the same guy that built his whole clone in, what, 2 days?

he's nuts...

JD - if you are going past that store again might you be able to pick a pair up for me and ship em to the UK? I cant find anything here and we dont have that particular store over this side of the pond. If not dont worry its a hassle for you i know, send me a PM if you like, they just look really good! lol

langsuir...that not a problem...i'd be happy to do that for you....they were only 10 bucks USD...send me a shipping address and i'll let you know when i grab a pair and what shipping would be...they had a small leather strap near the wrist but a quick snip took care of that. I know that the only female pair there at the time was the one i grabbed, but ill keep an eye out as im sure they will get more...

brian, you should talk youre as bad as i am...the thing is...when im in the middle of a project...i go non-stop till it's done...it's a sickness and one that is ticking my wife off cause she really wants to put some time into the construction...it's just so hard for me to stop once i get going...i hate being idle

tony, thats the DTG book (swatch-less)

Originally Posted by JDFett

when im in the middle of a project...i go non-stop till it's done...it's a sickness and one that is ticking my wife off cause she really wants to put some time into the construction...it's just so hard for me to stop once i get going...i hate being idle

I'm the same dude, LOL. Just not married. Becky (Langsuir666) feels the same so lately I've been doing other stuff for myself.
Shame we're dudes, hey? Cool costume is Zam.

If you can get her the gloves that should help, a little

beleive me...i thought about making a spare undersuit just so i could wear the thing..LOL i figure heck...she wears all my costumes!

(side note....she says there is no way i'll ever be caught touching her costume, other than helping on the build )

Originally Posted by JDFett

beleive me...i thought about making a spare undersuit just so i could wear the thing..LOL i figure heck...she wears all my costumes!

(side note....she says there is no way i'll ever be caught touching her costume, other than helping on the build )

you got that right pal!! the fun stops for you at the time of completion...sorry! i have to fight with him to get my hands into the mix!

Originally Posted by clawdite77

you got that right pal!! the fun stops for you at the time of completion...sorry! i have to fight with him to get my hands into the mix!

She Speaks!

JD - I'm telling you, work out the same deal I made with my wife...

You get the pride of wearing one of the coolest costumes, I get the pride of making it!

Her time will come!

WOAH!!!!!

she snuck up on me and got herself a name here at the great dented helmet...
nice to see you here baby!!!!


trust me Tony...she wont go for that

Hmmm.... and I've been working on this blasted costume for years.... Where were you guys when I needed you eh?

Originally Posted by MaulMaus

Hmmm.... and I've been working on this blasted costume for years.... Where were you guys when I needed you eh?

If it weren't for all these references on these pages, I would probably be in the same boat as you. You all laid the ground work for me and many others!

Originally Posted by JDFett

brian, you should talk youre as bad as i am...

takes one to know one! i spent the night working on 3 different guns for 2 different costumes, all at once!

we are a couple of costuming freaks...but thats why we get along so well

i mean who else could really stand to be around someone like us?????

quick question...

has anyone tried this stuff after making the leather parts to seal them?

http://www.montanaleather.com/meltonianwatershine.htm

i was also wondering about using lincoln dye preparer...for the vest, gaunlets and shins mostly, prior to using leather paints on them...

http://www.montanaleather.com/linc180.htm

Originally Posted by ItsThatGuy

Edit: Also, do you have a item number for those gloves? I'm still looking around for a nice pair.

Not sure if you saw this post from above...

BTW Wish I could help with your leather questions, but with this costume, it will all be my first time working with leather. This costume is going to push my talentless mind to its limit!

okay..when i grab becky a pair i'll check..worse case senario is i can grab you a pair as well and ship it to you

Originally Posted by JDFett

quick question...

has anyone tried this stuff after making the leather parts to seal them?

http://www.montanaleather.com/meltonianwatershine.htm

i was also wondering about using lincoln dye preparer...for the vest, gaunlets and shins mostly, prior to using leather paints on them...

http://www.montanaleather.com/linc180.htm

Never used either of those products so I really can't tell you. (Yeah I know... I'm no help what-so-ever! )

To seal the leather after dyeing I've always used Super Shene, Satin Shene or Lexol to finish the leather. I live in Arizona... waterproofing is not an issue

To prepare the leather before dyeing ... If it's new fresh leather, you don't need that stuff. If you're painting over leather, you'll need the deglazer. If you want to dye leather such as the white pigskin, I suggest you follow MonCal's advice and wash it in the washing machine with the Fels-Naptha Soap (He posted the "Recipe" on the forum here somewhere.) It gets rid of the extra stretch of the pigskin and the shiny finish allowing the dye to take better. So again, you don't need that other stuff.

Originally Posted by JDFett

okay..when i grab becky a pair i'll check..worse case senario is i can grab you a pair as well and ship it to you

I really appreciate that!

We don't have an Agway around here, but they have a website. They have womens gloves listed, but there is about a bazillion of them on there.

Originally Posted by MaulMaus

To seal the leather after dyeing I've always used Super Shene, Satin Shene or Lexol to finish the leather.

jd - i've got a quart of super shene here. you're welcome to take a bunch of it to play with if you want. that's more than i'll use in a lifetime... a throwback from when i used to do leatherwork vaguely full time.

thanks

Originally Posted by JDFett

we are a couple of costuming freaks...but thats why we get along so well

i mean who else could really stand to be around someone like us?????

Yeah, no kidding. The two of you!

so i had to work a little bit more while Jamie was at work...I know she will be mad that i did more...but she should be smiling inside at the result

anyway....here are a couple more pics...

did a bit of weathering on the boots...the other nulife spray came in this morning and i couldnt resist...used my clone trooper rubber cememt technique...if you put rubber cememt on just about anything your weathering, you can control the design, based on what is covered with the rubber cement...its a fast process with instant gratification...after putting on the RC, spray like you would normally, when dry the cement rubs off easily and reveals your weathered design. It actual shows like chipped paint...very cool..

also decided I really had to see the armor together...so i finished these

and now it looks like this


i used a various amount of method to combine the pieces...drilled holes directly through the side of the middle hose connector piece, top and bottom...and then ran a piece of coat hanger through the hole and secured with leather strips to the backs of the leather areas like so...

I then used some screws that i dremeled down to be super short for the middle piece and connected the two sides with a strip of sheetmetal

here is the back of the armor with a full view of the connections...all we need to finish for this whole piece is the ovary bits that hang off the rocker

that's looking really great.

Looking good! I'll have to keep that rubber cement trick in mind!

i swear....im gonna.....grrrr....but yeah it looks darn good baby!!

however i am going to start keeping this costume under lock and key if you dont knock it off!

Originally Posted by clawdite77

i swear....im gonna.....grrrr....but yeah it looks darn good baby!!

however i am going to start keeping this costume under lock and key if you dont knock it off!

Haha! You guys are funny!

Hey JD if you really want to work on this costume so badly I will send you Aimee's stuff to work on! I will even let you work on it for free!

Loving it! Great work guys

Anyone got any good tips for keeping the hoses inside the cross shaped part?

i plan on using a small flat head screw...like the ones used for computers

or two part epoxy...? The screws would probably be a better way to go, as it is removable.