Darktrooper Progress Thread 8MAR2011: Getting back to it

  1. #776
    Jangojedi's Avatar
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    Re: Darktrooper Progress Thread

    Chris, sounds like "dremel tool time"; cut here down to size and resculpt with clay (oil or wax based, that way you can pull a mold).

    BTW, I will let you know on the forearms.

  2. #777
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    Re: Darktrooper Progress Thread

    tubachris85x said: View Post
    Well the good news is that I was finally able to make the shoulders the right size and it fits me perfect.

    The bad news, is what I had feared earlier, that my chest piece is too big. Yep, I just wasted alot of fiberglass

    -TC
    What do you mean by 'too big' Chris?

    Is it a seam issue? or does it expand too far past the side of the chest so that it doesn't have a proper curve.

    This by sound silly....but have you tried the idea of scoring and cracking it to the right shape? (only if you've been using fiberglass weave, not bondo)

    you might be able to correct your curve and then smooth it out again

    just trying to help you salvage your work

  3. #778
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    Re: Darktrooper Progress Thread

    CombatBaby said: View Post
    What do you mean by 'too big' Chris?

    Is it a seam issue? or does it expand too far past the side of the chest so that it doesn't have a proper curve.

    This by sound silly....but have you tried the idea of scoring and cracking it to the right shape? (only if you've been using fiberglass weave, not bondo)

    you might be able to correct your curve and then smooth it out again

    just trying to help you salvage your work
    This is what I've actually been thinking about, the scoring/cracking thing. My first mistake was that when I fiberglassed the upper chest (the larger flat section) I made it completly flat-it is supposed to bend down the center. So what I'm thinking is cutting a straight line down the center (not cutting all the way through) so that I can bend it the way it's sopposed to be. From that, I'll re-fiberglass it as it sits in the proper shape.

    As for the sides..I'm going to have to trim them if I want to be able to salvage them. When the center is shaped after I score it, it should theoretically push the upper portion of the chest closer to each other (in a sense) and I'll be able to use it. But right now, until I can get that bend back into the center, it won't look right. One more thing to add-if you notic, the 3d chest/back has along the edges of the piece, a "wall" to appear thick I guess, but I'm going to be cutting those off to make it appear as the thickness of regular vac-formed armor.

    So yea...

    Jangojedi-Unfortunatly, I'll only be using this piece as the final chest. I'll be bondoing it, and scuplting the rest of the details via bondo. I really wish I could afford to mold the pieces, but it's just not at this time. I'll update you as soon as I can about the arm molds.

    Thanks guys

    -TC
    Last edited by tubachris85x; Feb 5, 2009 at 1:11 PM.

  4. #779
    I helped at SDCC '08 GCNgamer128's Avatar
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    Re: Darktrooper Progress Thread

    I say vac it. Fiberglassing means it will only fit one specific body type.

  5. #780
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    Re: Darktrooper Progress Thread

    I definitely agree with GCN, however if it is not in the budget, FG is very cheap. If all you want to do is a one time version. I have made many things out of FG and then pulled a lighter weight and flexible copy. The major problem, that everyone know with that is it will crack and chip everytime you handle it.

    Hey Chris I will post some more pics here later today.

  6. #781
    Ijaat Ka'rta's Avatar
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    Re: Darktrooper Progress Thread

    I've been watching this thread from the start and I must say this is really impresive. There is not way I would have been able to accoplish this in any way shape or form. Keep up the good work!

  7. #782
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    Re: Darktrooper Progress Thread

    The only cheap way I know of to vac-form this would only result in a one time cast, because I can't see it lasting for more then one, maybe two.

    :/ If I can talk to my guy whos going to be forming my arm pieces, but even then, I don't think his vac-former would even be large enough for the chest. The way he does his bucks, is that after he sculpts it, he fills the interior of the buck, and the outside with this really dense foam, from smoothon I think, and sands the excess, molds it, and then makes a solid cast in a high strength resin

    The foam itself goes for about $90, then pluse the silicone, could be about $150, just for the one mold...so yea..

  8. #783

    Re: Darktrooper Progress Thread

    Very nice work. Gosh soemtimes I wish I had half the talent of some of the people here!

  9. #784
    Jangojedi's Avatar
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    Re: Darktrooper Progress Thread

    Hey Chris, Here are my pics of my Prototype 1 (FG & gray) 34 cm tall and my Prototype 2 (FG over paper) 28 cm tall. Rc bucket is PA gear, FX Stormtrooper for comparison, what size do you think looks best? I am thinking the smaller one since this will be only an armature to lay some bondo on and sculpt (sand) the face details in & overall smooth out everything.

















  10. #785
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    Re: Darktrooper Progress Thread

    Hmm...The templates size that I inititially made my pep helmet was based off the height of the FX. I found it to fit me well, proportion wise. I would say use which ever one is best in comparison to your size. The addition of bondo won't or shouldn't make it too much larger, just heavier, really, so I don't think you'd need to worry about that, but that's just my oppionion, it's looking good!

    -TC

  11. #786
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    Re: Darktrooper Progress Thread

    I actually built one at 30 cm last night, which I am leaning to. I will definitely clay up and sculpt in the detail then take my transition mold. And cast in light FG outer layer then back up with rotocast.

  12. #787
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    Re: Darktrooper Progress Thread

    Sounds good man. Either way, your going to have ALOT of room inside. I think the bigger the head you have the better for this kind of helmet. As long as it's not a bobble head lol.

    I've been thinking about just casting them in straight slush cast/roto plastic resin. I feel that fiberglass might be a bit heavy, but a light cast might be good. lol I don't seem to have much luck fiberglassing anything, so casting a helmet in it for me might be a miserable failiure rofl

  13. #788
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    Re: Darktrooper Progress Thread

    tubachris85x said: View Post
    Sounds good man. Either way, your going to have ALOT of room inside. I think the bigger the head you have the better for this kind of helmet. As long as it's not a bobble head lol.

    I've been thinking about just casting them in straight slush cast/roto plastic resin. I feel that fiberglass might be a bit heavy, but a light cast might be good. lol I don't seem to have much luck fiberglassing anything, so casting a helmet in it for me might be a miserable failiure rofl



    fiberglass should be pretty light Chris, I always felt like any of the 2 part rotoplastics by smoothon made heavier items than those made out of fiberglass


    i could be way off though and not be taking into account mods, and range finders and internal stuff.

  14. #789
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    Re: Darktrooper Progress Thread

    It can be alot of things, really. I guess the only thing I'd be afraid with when it came to using the plastic resin, is heat warping. I've heard of that happening with some helmets, so I might have to man up and just go with fiberglass.

  15. #790
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    Re: Darktrooper Progress Thread

    The answer to that is "it depends". It depends if you use Isotalic resin, lay up resin, etc... some resins actually will never cure, giving the warped looked after a few years. I personally experienced this in laying FG Lamborghini Countach kit cars in the 90's.

    But with the micro sphere balls, it will make it light weight and increase the strenghth, but as Combatbaby has said, the rotocast will actually make it heavier. FG outershell allows people use bondo easier on the outer surface.

    Shoulders next for bro while sculpting the face, waiting on Fedex for my KLAY.

  16. #791
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    Re: Darktrooper Progress Thread

    True that. Smoothing with the clay will really help out though.

    In regards to the shoulders, I think I found out how I'm going to suspend the whole thing. Where I see you built the whole underside, I didn't, I found just trying to do it for the smaller ones tricky to get glued in right place.

    Sorry for the really bad pic, but you can see how it's sitting on my shoulder. I feel this is sitting in the proper postion, and even if I raise my arm parrellel to the ground, the shoulder bell stays in place, as per reference with the 3D model


  17. #792
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    Re: Darktrooper Progress Thread

    Dude, it's the face of God!

    But seriously, you can raise your arm with the shoulder piece not raising up? Or am I misunderstanding that... That sounds very impressive.

  18. #793
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    Re: Darktrooper Progress Thread

    askywalker98 said: View Post
    Dude, it's the face of God!

    But seriously, you can raise your arm with the shoulder piece not raising up? Or am I misunderstanding that... That sounds very impressive.
    lol thats exactly what I mean. I might go ahead and take another pic for clarity and from the side so you can see how it's sitting

  19. #794
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    Re: Darktrooper Progress Thread

    Hey it looks great. Quick question about the back pack. What did you use to attach the folds from the metal? I mean after the tape that is...

  20. #795
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    Re: Darktrooper Progress Thread

    orionx42 said: View Post
    Hey it looks great. Quick question about the back pack. What did you use to attach the folds from the metal? I mean after the tape that is...
    Hmm...I'm not exactly sure what you mean? I'm assuming the vents? For that, I just took a metal vent panel from home depot, cut the strips out, and then used a flat piece of styrene in the proper shape, layed the strips over it, bent the ends over the edge of the styrene and used hot glue to hold it down

  21. #796
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    Re: Darktrooper Progress Thread

    Well, I'm doing a modification to the helmet sculpt at the moment. The biggest thing that made me dread working on it, is that the empty space that still exist, the walls, despite being fiberglassed, are still very flexible, and trying to actually scuplt anything is just frustrating and requires more work then it should.

    So what I just did, was, well apply more of the expanding foam (I know, I know..) I'm doing it it incriments this time. I'm planning on filling out everything this time so that there will be support from all angles, internally.

    Should work....

    -TC

  22. #797
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    Re: Darktrooper Progress Thread

    How many layers of FG did you use? I personally did one coat, then fiber and then two mor coats and it is holding up to dropping, bondo and sanding.

    Here what I have so far, needs lots of work.











  23. #798
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    Re: Darktrooper Progress Thread

    I only did about one layer, but I guess that just means I suck at fiberglassing lol

    Yours is looking great so far. The only thing that I have to say about it, is that the brow over the eyes appears to thick, but that's just me

  24. #799
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    Re: Darktrooper Progress Thread

    Yes, you are right Chris. I always build on the thick side, then after I sculpt in the facial details, which will bump out a little bit, I will bring the brow back. Right now, globs of bondo on there to work with. The brow is not straight if you really look at but that is because I am not in detail mode yet. It is a fun process.

    As far as FG-ing, you don't suck. It is a process of doing some things. Like I just figured out how to sculpt with bondo, you glob it on, and then take a cup full of acetone and a paint brush and brush out the high bumps or curlys before it sets up. It is really helps on the sanding time.

  25. #800
    tubachris85x's Avatar
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    Re: Darktrooper Progress Thread

    Got some more work on the sculpt last night, started to focus on the lower face area. If you compare, I've narrowed both sides of the upside down "U" shape, and have begun sculpting the greeblie in the middle. Unfortunatly, the greeblie detail from my references is only clear enough on the top portion, while everything below that is just "black" and any detail lines are non-existant or noticable. Because of this, I'm forced to interperete the rest of it, so I cannot say that this piece will be accurate. It still needs alot of clean up work though, and I'm thinking about making this a seperate piece until I make the final mold.






    Just a side profile to get a better feel of the shapes



    -TC
    Last edited by tubachris85x; Mar 16, 2009 at 1:19 PM.

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