General New member considering Zam Wesell

I've run into issues with the body suit thread popping loose. We're now going to resew in polyester upholstery thread.
Some comments from those who'se done this dang thing would be an awesome help about now.
 
Can you provide any more information besides the name? Threads come in varying thicknesses. Is it polyester or cotton or a blend? Honestly, this is the third time to sew this up and after all I've done now, this holding me up is frustrating me to no end.
 
Ok, so 100% polyester. That's what I've got now, and it's super tough to withstand stretching for vinyl and thick cloths for furniture fabrications. We're also going to try a different stitch length and size, see if that holds up better too. I'd have this costume at 90% done by now if this bodysuit would just come together right for me.

For the time I've been quiet here, I've layered my helmet with resin. I'm hoping to have another layer with the fiberglass meshing done today. How many coats of resin do you think it'll take? I'm guessing about 6 more. I need to look at some threads regarding resin coating and the bondo body-filler coverage so I don't screw this up. I've also been working on making a Bultar Swan Jedi costume for my daughter, and a Jango Fett for my son. My daughter's costume is nearly complete; It just needs two leather pouches made, a black wig, and some brown boots. She needs some for winter anyways. Jango is in progress. I'm to a point where I can place his "armor" on his blue overalls. Armor is silver spray paint covered rubber matt. It's lightweight, flexible, and I'm hoping will take the goop glue. I'm going to have to buy him a helmet. I haven't begun his arm guards.

So, I've been busy at work on this stuff, but not alot of progress to show for now. I have some pictures, but haven't posted them yet. Between the kids back to school and trying to maintain a large garden.. I'm spread a bit thin.
 
I've been working the helmet now. I've uploaded images to the Zam folder of photobucket if anyone is interested :) SW Zam by silvermittt | Photobucket

Working the helmet is interesting. It's a bit of hurry up! (coating application) and wait! (for it to cure and repeat it all a few more times). I think 4 layers of resin with fiberglass is enough. Too much will make it heavy. After this dries I'm going to apply the softer stuff. My best guess is a 2-3 thin layers to make it about 1/4 an inch maybe? Opinions from others who've gone this route would be awesome. Also, I would like to add (for those as new at this as I am) that the cleanest way to do this is use spray adhesive with the mesh fiberglass. It's easy to cut and doesn't leave alot of bits of fiber everywhere unlike that matting. That matting is a hairball nightmare when covering it with resin. The mesh is so much easier, so if you can get it, I highly recommend it. So far, the only way I could find it was in the bondo kit. I didn't need a whole new kit, so I bought the matting, hoping it would be as easy to use. I used it, but did NOT like how it balled up on me. I'm posting two images to show you the differences in appearances between the mesh and the mat., and how it all looks after sanding down.

#1 mesh on outside of helmet
IMG_1787_zpsaetgkt6w.jpg


#2 is the coting over resin sanded down
IMG_1790_zpszaqwxkp5.jpg


Once the helmet is done enough to use, I'll fit the face veil and mock hood to get it to look right. I've got them ready for finishing touches. Which leaves me with a cranky bodysuit and gauntlets I can't afford to buy just yet. I've been working in between cure time on my daughter's Jedi Bultar Swan, and my son's Jango Fett.
 
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Help, please?
I'm trying to replicate the parts of the helmet I'm going to have to sculpt. I'd like to know if these are close enough? I'm aware that there are some sharp points that are supposed to be soft curves, but that will be actualized sculpted parts. This is just a working image to refer to.

UPDATED: changed it up a bit.

helmet%20pieces_zpsdoi8kh9t.jpg
 
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I can hand correct my print and work from that. I appreciate your help very much! By the way, does anyone see a stylized ferret face with that round one?
Hmmm.. if I elongate the black parts going inward, yes definitely! Ferret face. Zam was a ferret lover, I knew it!

:love
 
Just wanted to mention that I got a couple of the Bushnell binoculars coming to me. I'll probably have them next week sometime.
As I'm working on the helmet currently, it'll be nice to have all my parts ready to put together.
 
I've got my binoculars, but I'm still thinking about the metal strips. I don't find them, so maybe I have to build them with aluminium. My husband said it is moldable, but I'm not sure if it will work.
 
Hmm...I haven't looked at that much yet. My husband's the hammer -handy type and would know what I ought to look to use. I'll let you know what I'm going to use when I get to that, mirval.
 
I bought second-hand helmet, I had fix parts and I sanding and I've repainted.
When I bought the helmet also I bought the armor of binoculars.
I built the binoculars with pieces of two new binoculars.
I boutght nuts and screws and i made the piece that goes in the ear where the veil is engaged.
 
Hey all. I may have to hold a funeral for my dremel and oscillating tools. Seriously, I almost smoked the oscillating( currently cooling down) one with the sanding attachment on my helmet today. I actually did kill my hairdryer using it on thermoplastics a month ago. Who knew the way to test the quality of small appliances was through costuming! :facepalm

I can say that I've almost got it ready for another picture and then I'm patching the few places that I discovered holes. After I get that, I'll etch out the linework. When I've got more than 3 images to post, I'll get them on photobucket.
 
Well, I've been quiet on board lately, but I have stuff to share now. In between working on Zam, I've been putting together a Jedi Bultar Swan for my daughter, and a Jango Fett for my son. Currently, the only image I have of my daughters costume is the undyed belt, shown with the Jango belt. (Today, we get the wig cut, so I might be able to post that update if anyone is interested -- I will be posting it on the Rebel Legion's board). I'll get her to put it on and I am going to upload it on photobucket later. All I need to do for my son is pad the helmet I bought, and make gauntlets. I cheated on the jetpack and bought the backpack he can use for school if he wants. His gloves, nice as they are, are too big. I'll find a new pair for him next week, I think.

SW Galactic Academy by silvermittt | Photobucket


As for Zam, the helmet has been an experience. Today we got a piece of drill press tool to make perfect circles on the ear cuffs and I'll be etching the rest free hand today. The greeblies are baking in the oven as I type this. They will need to be sanded a bit and perhaps cut the edging a bit deeper. The helmet has it's line work etched in. I've got it ready to start attaching tthe earcuffs and greeblies. I also worked on the rifle parts some and have them ready to attach. Not sure when it'll be put together as I am waiting for the scope to be completed before we put it all together. It takes time, something I am running short of now.
SW Zam by silvermittt | Photobucket

And for fun, I have to ask: Why didn't Zam just buy some decent scotch and slip those arthropods in it and have it delivered to Padme instead? Think about it, it would have been a win-win all the way around for the bounty hunters and Empire if she'd have done it that way instead!

IMG_1817_zpsk7bmacuw.jpg


IMG_1818_zpsqaqgrt8y.jpg
 
Note to self: Do not make Zam greeblies while drinking a heavily spiked Irish coffee.:cheers I made two right side earcuff greeblies. LOL!

That's ok, I didn't like the way my circle one turned out and am going to remake it. So I'll make a left greeblie too.:facepalm
 
I really need some feedback on the helmet. I am not real happy with how it ended up looking so far. But the earcuffs are balanced now and attached to the helmet. All I need to do is secure the greeblies on. Since I screwed up and made two of one side, I'm baking a new one. I also didn't like the way the round one looked, so I've remade it too. My helmet isn't like the one in the books to me, even though i used the pepakura file and sized it to me.. *I'm frustrated!!*


SW Zam by silvermittt | Photobucket


I'm to the point that I just want to know if this thing I created is even remotely close to 501st approvable, sans the greeblies and outer metal paint covering. If someone could take a look, please look at the latest 4 images posted. Thanks.
 
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