I've been playin' around with Smooth On's "Foam It" and "Flex Foam" products for a while, with little, single parts and things;but have yet to do a full size,'Stunt' peice.
While at an armor party with the Old Line Garrison, I was challenged by some of the members, including Scott and Charlie of AW Studios, to make a light, full foam pistol or rifle for trooping. Having squired once before, I've already seen my share of dropped E-11's and FX lightsabers.
Since I've been a Ghostbead for the last few years, it was refreshing to do a new prop. So, to start out slow, I picked the Biker Scout pistol.
Reference was hard to come by, but since I was doing a rubber stunt version, noone had any objections to using the heavily used stunt from the Visual Dictionary.
I scuplted the master from sintra sheet, resin, and putty. I was able to get an old, nasty mold from AWS and contact they had in the 501st, and I used bits from that to create the 'rodding' along the top and side.
I also was lucky to get to play around with a Sinlgepoint scope, and then scratchbild a nice look-a-like for casting.
I did a simple jacketed two part mold, buffered in foam instead of fiberglass. Once cured and split up, I painted in Flex Foam 25, dyed black, which expanded twice it's depth, and formed a nice, solid rubber outer skin.
Once semi cured, I put the entire mold back together, and poured in Foam It 5, which expanded out five times and has a softer, more 'nerf' quality.
Once pulled and inspected (nice, thin mold line , air pocket in the rear :evil, I coated the sucker in some Plasti Dip aerosal, and weatherd it a bit with a silver sharpie. I also cut, bent and screwed in a nice little trigger guard, and superglued the scope on.
What do you think of the first pull??
Hope you guys like it! If I can do few more decent pulls, the plan's to expand out to ROTJ D-17's and ANH E-11's. I may even attempt a full "stunt Proton Pack!