Mand'alor the Uniter. V3.0

Winter is here for me, so I usually spend it down in my shop working on armor or at the forge working on a knife. Ever since I finished my 2.0 armor that most people have seen me in over the last few months...the only thing I can think about is the next set and making it better. So, as I do on Mercs I'll be posting a work log here also.

This set of armor is very special to me, because it will encompass every ounce of skill I have in metalwork and electonics. I'm sure I'll be learning some new tricks and techniques as I put it together...as you just can't know it all. For all intents and purposes, this is also my last personal set of armor for hopefully many years as I begin working on sets to sell.

I'm installing quite a few new innovations that I've been working on over the last year. A working RF, compressed jet-firing JP, and modular armor system are the three big projects that go into this set. Many future upgrades are planned, and with the nature of this build there will be no need to replace an entire set, just add on. =)

So, lets start with the Jet Pack. Firstly, I used Skupilkinson's JP patterns for a Jango arena pack. I've always loved the arena pack because of it's more sleek look. Now there will be quite a few customizations to the pack itself before the internals are even installed. Pictures are in sequence of order, with the final picture being acompairison of it next to my modified Boba fiberglass pack. I still have the center strut to add to the ouside of the canister as well as a couple small parts before the fuel canisters can be added.

The metals used are 26gu plate steel for the base, top, bottom and outer fuel canister holders. 25gu aluminum for everything else to keep it light. At this point it weighs about 5oz less than my fiber pack, and I don't expect the weight to be that much more in it's blank state. Once the NOS jets and canister are added, I expect it to put on a few pounds. The goal of this pack is not to *fire* but to blow out 2 jets of N20 gas illuminated by 2 ultra-bright red LED's for a working effect. Anyone worried about N20 shouldn't as it's a stable inert gas. =)

I am going to enjoy this thread so much

Well this is odd?I just started back on my metal pack also, after a little hiatus.We must be on the same wavelength.lolol
Lookin awesome so far bro.

Originally Posted by wickedbeard

Well this is odd?I just started back on my metal pack also, after a little hiatus.We must be on the same wavelength.lolol
Lookin awesome so far bro.

Took me 2 weeks to get this much done. Just found out my cousin down the street has an industrial sized lathe...so guess what I'll be doing? =D

looks pretty cool noval look forward to watching your progress

This is going to be awesome! :thumbup It makes me want to try making a pack out of the thin sheet metal I have at home

that's an ultimate.

I love it!

wow... metal rocket pack. that's hard core!

26gq. metal... how tough is that? will it bang up easily?

wow. this is awesome!!! I want one!!!

Are you welding the pack together, or cold welding it with JB weld?

Also, are Skip's templates on here somewhere, or would I need to get them from him?

Can't wait to see this finished!!! Post tons of pics, please!!!
A'den

Goop with JB weld on the seams for added strength and as filler. No need for a hot weld using both those, it's tough as nails.

You can find the papakura template at the bottom of the Mercs tutorial/template library, but you'll need the papakura program (free download, just google papakura) to view and print it out.

Mandalorian Mercs Tutorial Library

Great job on the armor Keep up the good work

Amazing work Novall!!! What kind of helmet are you going to use this time?

I'm putting together a metal helmet of my own design for this set. It will have some similarities to the MS custom I use now as well as some traditional changed (RF moved back to the right side) and some designs of my own creation. =)

Pretty polished metal! verry nyce!:jet pack

Hmmm... Metal jet pack... that's why my last one burst into flames...

Forgot to mention that it looks awesome! Lol:thumbup

Ooh! Shiney!!! I can't wait to see more, you just now it's gonna ROCK!

I'll be following this with great interest NT!

Ahh the wonders of JB Weld... Incredible workmanship. I can't wait to see the nozzle assembly

Here's the pack all sealed up at this point. Working on the canisters and missile ring at the top currently. Have the ring on in this photo to get a good bearing on how it's gonna sit.

Good Skills man, keep going!!!

Beatiful work NT!! I'd love to have the knowledge for these kind of builds!

Honestly, it's not much different than making one out of sintra or think plastic. Cut, bend, goop and JBweld. Thats pretty much the entire process. This is MUCH easier than making armor. It's only taken me like 2 weeks of total work time to get this far.

Really? Do you need a welding torch? I've never worked with metal before. I may have to try it out next year.

You can't really weld metal this thin. I'm using a mix of steel and aluminum, and it's fairly think so I can bend it with pliers and a good vice.

I've used my best pair of tin snips to cut all the pieces out, so you only need a dremel to grind down some edges.

Thanks again NT. I think I'll need to follow threads like this even closer.

metal jet packs....brilliant

Welp, after ALOT of thought...I had an epiphany yesterday as to how I was going to make my canisters. One thing that IMHO is a big difference when working with metal in regards to plastic or cardboard is that there really isn't much room for measurement problems. Many times for the smaller parts I have to fly by the seat of my pants and measure as I go so that everything fits perfectly...I mean this is metal, you can't just take a heat gun to it.

So I had some problems with the original canister templates that came with Skips jango templates, they were just to big for the wholes I had. Lastnight at my girlfriend's place...I had a light bulb go off in my head. Monster energy drink cans!!! The big ones with the twist tops, they should be about the perfect size, and if not the aluminum is thin enough to easily manipulate so that there's no damage to either the base or the can.

So, not only do I have my canisters now...but with the screw-off tops I now have a nice way to take the nozzles and cones off the pack for storage/travel. Pretty nifty eh?

Thats our Mandalor, Always flying by the seat of his pants.LOL

Great work Boss, I'll have to save up for a set when you start makeing them.
Will follow this with interest....... I need a jet pack for my next build.

Great!! Nice idea too with the nozzles and cones. You tried my templates for this? Thanks for giving them a go buddy? Are mine or Alans templates being used for the main pack build?? Or are you going from scratch?

I used your jango templates for the main pack build Skip.

WOW! Thanks for the vote of confidence buddy! I appreciate it. I was super interested in this before but now I think I'll be sat here hitting F5 every 5 seconds to check for updates! LOL!

I'm really pleased they're working out for you boss.

They work great!

I'll be using your templates for my helmet base also to see how those work.

this is shaping up really really well. I love that feeling when you've been working on a problem for your costume and the answer just comes out of nowhere

Originally Posted by Apollo

this is shaping up really really well. I love that feeling when you've been working on a problem for your costume and the answer just comes out of nowhere

Well, the tank problem was really a very annoying problem because I knew at first that a normal can may not be strong enough to hold a cone...especially when high pressure gas is coming out of it. Those Monster drink cans are pretty stout on the top, and the twist off lids are solid aluminum. So I can basically build the rocket cone around that and go from there.

Thanks for the compliments guys. I'll post more pics as I make'em. I'm cutting out helmet patterns now. =D

Lookin good Novall.I used cans for mine as well.Not monster, but they are very similar.

I just like how the screw tops make it easy to break down the exposed parts for packing. Since this thing will be making many jaunts around the country...I need to make sure it stores better than my last one.

My problem right now is figuring out how I'm going to do the thruster cones. I have an actual dismantled RPG that will be used to make the rocket (either I'll use it to make a CC rocket or if it's not to heavy I'll just use it.)...so no worries with the top. Just the thrusters that have me stumped currently.

Monster drink cans...brilliant!!!

We are not worthy:thumbup:thumbup:thumbup

This is amazing!!! Keep it up!!!

I'll be posting some pictures of the thrusters tonight. I've had to make them out of 2 halves, roll and dish the proper curve into them. Each half was put together using a brace of steel on the inside of each seam. Currently I have JBweld hardening over the seams so I can sand it down flush. Now I just gotta worry about connecting them so the gas tubing fits up to'em.

Looking forward to it NT! I'd love to try something like this next year sometime.

Nozzles put together. I have to seal the top where the cone meats the attachment ring (they are removable for transport) with some JBweld, but all in all I think they came out great for something non-machined and hand curled/dished. I don't have any of the armoring hammers you would use to make fingers for gauntlets...so it was a pain getting these things rounded.

Now I'll be moving on to getting the top parts done before installing the gas kit.

Originally Posted by NovallTalon

Nozzles put together. I have to seal the top where the cone meats the attachment ring (they are removable for transport) with some JBweld, but all in all I think they came out great for something non-machined and hand curled/dished. I don't have any of the armoring hammers you would use to make fingers for gauntlets...so it was a pain getting these things rounded.

Now I'll be moving on to getting the top parts done before installing the gas kit.

Looks terrible. I'll pick it for disposal at ShevaCon.

Charlie

Originally Posted by charlie

Looks terrible. I'll pick it for disposal at ShevaCon.

Charlie

No dinner with Jeremy for you!!!

Wow! Looks amazing NT! You're doing an awesome job here bro!

She's almost done! Will be adding the guts soon.

A thing of beauty buddy! Wanna give it to me?? LOL!

Here is an updated shot of the pack.

Most of the outside work is done at this point (except the missile). The two air to air missiles on the pack are magnetically attached, so I can pop them on and off for transport. The turbo intakes (the cones at the top of the tanks) were made outta leftover jango pistol heads, some balsa wood (as a skeleton for the bondo) and bondo. There is a very very tiny amount of bondo glass used on this pack, most of which was covered with JB weld to add strength. The access panel on the inside surface is also magnetically closed..used alot of magnets since this is a mostly steel item.

On the bottom between the thrusters is a control box that will show when the pack is powered on, and when I hit the button to charge the CO2 system.




And of course here is a picture of whats done on my new armor currently. This is all 14gu aluminum, hand hammered and smoothed. The shoulder bells are done but not pictured at present. Left plate as a little more curve to accommodate the chest display electronics.




And this is a new set of armor I've made for my girlfriend. 22gu steel, hand dished/planished.



I made this much in about a week, and it will fit a B cup...so hopefully at some future date I can actually make this for lady mandos. Female armor is infinately harder than male armor because it is absolutely necessary to have either:

A) the girl on hand for fittings, or
B) a well made tape cast of the upper body for fitting.

you are a master of the metal NT, and an inspiration...literally...my friend just saw this thread and said " dude we can do that!" lol i may need to knock some sense into him

Nice. A beautiful build. Your work is magnificent.

Thanks guys! It gets easier over time, but it's never *that* easy. The JP I've been working on since December, but now I gotta start devoting more time to getting the armor done. Need it ready by mid-April if I have any chance of putting together a metal helmet in time for SDCC.

Not to sound like a criticism, but do you know that the raised parts on either side of the main center tube are upside down? Was this done on purpose because its a custom build? Either way, it look freakin' amazing, btw! That's some crazy skill there!

Gooooo, Monster enery drinks!!! Recycle, use your unwanted Monster cans on the project you're working on! Perfect for jet packs and such!

JK Mand'alor, just happened to pick that up lol :thumbup

What's your address and when are'nt you at home?

He keeps all his gear in a indistructable safe anyways. Trust me on that one....

Originally Posted by Shinobi_Fett

Not to sound like a criticism, but do you know that the raised parts on either side of the main center tube are upside down? Was this done on purpose because its a custom build? Either way, it look freakin' amazing, btw! That's some crazy skill there!

Yes I did put them on upside down just to change things up a little bit. At first I was gonna go with those inner panels the normal way, but the didn't seen to want to sit nearly as good as they did upside down. Also, I felt it added a more aerodynamic look as they have a curve and slope downward where the opposite side is just squared off.

Yep, monster energy drink bottles make up the tanks because they were almost a perfect fit. Also, the metal caps stay on very tight which allowed me to use that as a way to take off the thrusters and forward turbo intakes for "collapsible" carry mode. I just screw'em back on when I'm ready to suit up. Personally I hate Monster drink, took a taste and almost thew up...so I poured them all out. Was kinda funny how I came up with this idea as my girlfriend drinks redbull like a fiend. I went to the store to by her more and the monster can sang to me "use me on your jet pack!!!". So I did and it works like a champ.

MYSTRIVEN, I have killer ferrets who are trained to attack anyone they don't know. =P

Nice!!! I love it.

Any concept pictures or sketches for this armor ner'vod or is it a suprise.

I don't normally do concept sketches, and my pictures come after I complete a good amount of work. My paint scheme will always remain the same at this point, and I don't really let the cat outta the bag before I give the suit a proper opening.

I am going to try to have it done in time for AdventureCon in Knoxville TN, but if not then I will definitely have it ready for SDCC.

Working on the center missile.

For the center missile, I was given an old dud RPG rocket. These rockets are almost completely made of copper, contain a large copper core (for shrapnel) surrounded by what looks like hardened clay filler (what they put in when they pull the HE paste out). I broke out all the filler to make it hollow for weight, filled in on of the large dents, and created a hard leather shim for the missile to sit tight in when I put it inside housing shaft. I am going to make some fins to go on the base, and maybe stick some kind of old burnt out model rocket engine in it to make it look like an actual concussion missile. Anyhow, here is how the JP looks in it's 98% finished form.

Nice good. That female armor is looking great.

Sweet rocket NT!

Great progress Novall!!!

Originally Posted by NovallTalon

Working on the center missile.

For the center missile, I was given an old dud RPG rocket. These rockets are almost completely made of copper, contain a large copper core (for shrapnel) surrounded by what looks like hardened clay filler (what they put in when they pull the HE paste out).

Nice work so far. Just one thing quick thing that's completely unrelated to your work so far; the copper in the RPG isn't for shrapnel, it's the liner for the shaped charge warhead of the RPG.

Originally Posted by Riceball

Nice work so far. Just one thing quick thing that's completely unrelated to your work so far; the copper in the RPG isn't for shrapnel, it's the liner for the shaped charge warhead of the RPG.

was wondering if I should say anything about that...

LOL, well I learned something new. =)

Tomorrow I'll post the "finished" pics. The pack itself is done at this point, only have to install the guts and electronics!!

This is looking totally sweet man. Choice work. Give all as n00bs something to aspire to.
I am hoping to make my own set of metal beskar'gam sometime in the not so far off future so your work is highly motivating to me.
Big ups for the awesome job. 12/10
Tracyn out.

Thanks Tracyn. My job is to be the best for not only all who wear non-canon mando armor...but to help inspire more to heed the call of Mandalore and don their own awesome kits.

I began the concept of my 3.0 armor shortly after my 2.0 armor was created, and I think I started with the most difficult part first. I start working on a metal helmet this week, and will hopefully have it mostly welded together by the end of the week. On any armor project, set yourself clear deadlines.

Yipey!!! can't wait to see the finished project!!! and a metal helmet!!! post pics!!!

Ok, here is the finished pack in all it's greatness. I still have some greeblies to attach, and the control box on the bottom is still being wired up before I paint her. I also have a more detailed shot of the missile when it's not in the housing. I've tried very had to make this pack as 100% realistic looking and functioning as possible...so you can actually pull the missle out and replace it with another type of missile or attachemnt. I am very big into "Modular" armor for different missions.

The last 3 shots are comparison shots to a fiberglass JP. As you can tell it is almost the exact same size as a fiber pack, and weighs in at just about the same weight (without the C02 system installed.).

Beautiful buddy. Very well done!!

So you gonna knock up some alternative missiles?

I'm guessing by the fact that you mentioned there's an installed CO2 system inside that the pack will smoke on command as if it were a real jet pack, pretty sweet! Once you get it finished you have to post some video clips of it in action.

Here's an armor update.

Been working on my bicep and knee armor. Bicep armor is 18gu compressed aluminum alloy, lighter than stainless steel but just as strong. Same with the knee armor. I build my knee armor a little more square than the normal boba/jango knees for stability when kneeling, and because it's just comfortable due to my left knee being metal and slightly bigger than my right knee. I have to get my maintenance department here at work to weld the edges...then it's on to the dart launcher housing.

The right bicep houses a holo-transmitter. I took the LED's out of an old linksys router and put them inside the housing along with 2 batteries and a small switch. In power-on mode the lights glow green, and when I push the center button for xmit mode, the second battery switches on and the LED's glow yellow. Everything is housed inside the bicep piece, so it's in one nice neat package.

Very nice! I really like that bicep!

Thanks skip! I am foaming at the mouth to get ahold of your clone leg and shin patterns so I can get my leg armor built! =)

I'm seeing what I can do to get you sorted for shins today.

Man Novall you do good quality work.

looking good man, i really dig that jet pack!

Absolutely incredible

Thanks all. The hardest part isn't making the armor...it's making it work! =)

This stuff is amazing!

Here's some pieces I was working on this past weekend.

I've designed a very mando looking articulated heavy boot armor. 3 pieces hand hammered out of 14 guage aluminum and articulated (how we describe moving armor in the armorsmith world) to allow for maximum foot movement.

Also an updated picture of the stainless steel knees I've been working on. I decided to go with a heavier steel so that I can actually get down on them without worrying about breakage or bending. These are 18gu stainless, and the launchers contain small nickle plated brass darts. Just gotta finish capping the launcher boxes and the knees will be ready for painting. =)

Love those boots!!!!!!!

Updates!

Knees are done. I'm including a picture of one in the finished stage, and all thats left is putting in some padding.

Back plate is also just about finished. I have dished the piece out so that it conforms naturally to my back structure. I still need to trim the sides and neck up a bit and give it maybe an hours worth of planishing work, but other than that it is pretty much done. I've placed some extra pics of it in here so you can see the nice sweeping curves of the back, so if any of you plan to try to the same thing then you have some reference.

WOW! Well done there bro! That backplate is a real beauty!

Thanks Skip! Next stop...those shin patterns you sent me. =P

Hope they work out for ya buddy

Here is the left shin armor. Skip made me some of the clone shin patterns, and I used those to build off of. These are basically a longer Jango style shin guard with a back piece that fits inside just at the bottom of the calf muscle to keep it covered yet comfortable for all kinds of motion.

I put in some flutes both on the top right and left sides, basically these are for show but it's a very nice look that gives it a deeper appearance. My only problem is that the bottom front has a crack in it that I need to fill in with some aluminum braze. Once I get the right one done I can work on the sheaths for the knives that will sit on the front of each greave.

This is what it looks like at 75% done.

very cool

I'm liking the heavy four-spiked boots - very nasty! Isn't it hard to walk around covered in all this metal?

Wow O.O completely blown away, very nice work!

Originally Posted by Oddball Fett

I'm liking the heavy four-spiked boots - very nasty! Isn't it hard to walk around covered in all this metal?

LOL yeah, everyone loves my boots! =P

Actually, it's not that hard at all. Everything is articulated to fit perfectly and move fluidly. The greaves fit my leg muscle structure perfectly, so that makes them highly comfortable. The backs of them only go as high the bottom of my calf muscle and are rolled out just enough to keep from digging into my skin. Plus with this being aluminum, the entire boot armor w/greave may weigh in at 3 pounds max.

Great Work Novall!!!! I can't wait to see the new bucket!!!

I worked up my thigh plates yesterday. I was sitting in my workshop on Sunday trying to figure out how I was going to do the thigh plates, and as much as I wanted to make completely enclosable thighs...I realized that not only was that not practical but it was just going to be more armor that anyone would want to wear. So I took my Jango thigh pattern and stared at it for about 30 mins.

Then...it came to me!

I took the pattern of a 15th century cuisse (knight thigh armor) and put my jango pattern ontop of it. It was like they were ment to be put together. The wing that wraps around my thigh was actually hinged on the 15th c piece, but I figured that if I could give it enough curve then it would wrap around perfectly creating a nice "heavy" thigh armor that wasn't cumbersome. The idea worked, and after about 2.5 hours of hammering I had 2 great looking thigh plates ready to hit the wire brush.

I will be putting some brass loops on these to run my holster belts through once these are painted up and ready to go.

Also, once I am finished with this armor I will be making the custom patterns available for anyone who wants to use them. Most of these will work with sintra and plastic just as they work with metal.

looks awsome, quick question tho....WTH is in your tree?

One of the jet pack missles. =)

I hang round items so that I can get even coats of paint on them. Makes for a much nicer paint job.

haha!!! I was like ***!!! he's got an RPG in the tree!!!

looking sweet

Painting at this point is around 60% completed. Upper body and back plate are all that is left as far as painting goes, and that will take a day or two to complete.

In the mean time, let me thrill you with some video of the jet pack CO2 system test from this past weekend. This was a prelim test to see if the system would actually work, what voltages were necessary, how it looked/sounded so that tweaks and fixes could be made. The link below goes to the test vid:

http://www.youtube.com/watch?v=Ha0kImYIARk

Also posting up a pic I took of the pack before I hit it up with carbon dust and put some wording/graphics on it.

Posting a small update.

Chest/shoulder armor will be painted this weekend. I had ordered a custom chest display board from Fettronics with a little different light pattern than the normal Fett display.

For now, I will continue to use my current helmet. I have a metal helmet that I am working on, but it just won't be done in time for cons this year and my main focus is getting the body armor completed. Ladysewforus is working on a nice leather armor vest, and my local seamstress is working on a custom flight suit with earth magnets sewn in to hold the leg armor on.

I've also made some custom hand armor based off ST hand armor with some minor differences. I may go the full route and put some finger armor on...just depends on time.

I'll get some pics done up this weekend!

Everything looks great Novall!!!!I love that pack.