Budget Scratch Build

started my bucket today, but my card stock is way too thin, I guess I gotta layer a few pages together and give it another go. That and my printer is cropping my prints. How do I post a pic of my work?
 
never mind on how to post pic, I see I need to get past the 14th day, thats cool, it'll give me time to get my bucket in better shape and to get a few build pics ready to post.
I gotta say there are some really tallented people here, I hope I can live up to the standards.
 
To me it is amazing that someone can scratch build something like Boba Fett's helmet with a little time, a lot of effort and patience and the help of this board. Great Job, I can't wait to see it more completed.
 
....hmmmm, I don't know how many sketch books I have lying around. Where could I buy a large sheet of that kind of cardboard? I tried finding it before but opt'd for poster board since i was short on time.
 
....hmmmm, I don't know how many sketch books I have lying around. Where could I buy a large sheet of that kind of cardboard? I tried finding it before but opt'd for poster board since i was short on time.

Anyone? Seriously, I'd like to know. o_O
 
Your best bet is to look in an art or graphics shop.

I've heard this stuff referred to by many names: Fibreboard, mattboard, my local shop calls it greyboard.

it's also used for the backing of picture frames so lots of framing stores stock it.



hope that helps,
Tom
 
I was really questionable about using polyfiller, but now I have seen that it works, I'm off to get some. I found that the ever wonderful Mr Cheap has got some ex-stock near me so I'm off to get some now. If you have one near you , it['s well worth popping in on a lunch break and pickin up some cheap art stuff. I managed to get sculpting tools for about £1.
 
I haven't posted anything in ages because I've been away (doing an Architecture degree)

But now I'm back and have got thoroughly stuck into making my rangefinder.

First of all I purchased a metronone kit from Maplin as well as some green LEDs.

As soon as I got the kit I assembled it according to the instructions and then began to sync the lights up to the right speed (2.13 Hz), by adjusting the two pots to 40KΩ each.


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That was fairly easy and formed the basis for my rangefinder circuitry.

Next I desoldered the 9v clip, the LEDs and the capacitors. I re-soldered the capacitors, leaving longer leads so I could fold them down flat.

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I had to extend the leads of the LEDs, this was fairly simple, I just soldered on some short lengths of wire and added heat shrink tubing.

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I then re-soldered these longer LED's into place.
Also I filed off the unused areas of the board.

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Until I could scavenge another resistor (maplin only sell them in massive sets) I'm leaving the circuitry here.

Total spend is now £9.58.

- Large card for main helmet & mask : £2.00
- Pint o' PVA Glue : £3.00
- Metronome kit : £3.99
- Superbright green LED : £0.59
 
Next up is the rangefinder housing. If I remember correctly this part isn't detailed in either of Antman's threads
(which I have been following fairly closely) So I'll try to show a bit more detail.

First of all print out a set of WoF's templates from the gallery.

I'm using 1mm thick mattboard (scavenged from an old sketch book)
So I then began to mark the various places I would have to trim 1mm off of to keep the correct shape.

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The dotted lines show where I'm going to angle both edges at the corner rather than just trim one of them.

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Here are the pieces cut out.

I began to angle some of the pieces with a knife and sandpaper. I also drilled out the LED holes using a 5mm wood bit.

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Then I just began assembling all the pieces.

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I had to be careful, trying to make sure the sides were square.

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One of the pieces didn't quite fit, overtrimmed, but I'll sort that out later

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After letting it dry a while I decided to paper mache' the inside, to cover the small cracks and strengthen it a bit.

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Here is the housing after having been trimmed, polyfilled and sanded quite a lot.

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Then I brought out my circuit and did a test fit, bending the LEDs into roughly the correct place.

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The circuit fits easily into the housing. The only problem is that it infringes on the lens' space more than I would like.
But I can't be bothered to move all the stuff onto a smaller board.


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According to the WoF templates, the ESB rangefinder doesn't have that little lens on it, but I decided to make one anyway.

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The first step was to mark out the areas to trim.



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Then carefully cut the pieces out of 1mm thick mattboard



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I filed a v shape on the opposite side of this bend to stop the card wrinkling when I bent it.



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Then I glued the pieces together, careful with the delicate 'hinge' area.



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Here is the piece after some careful sanding.
 
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