Zannah's Armory


Dessel

New Hunter
Zannah's Weaponry

Well, here it is, the progress page for my work on Zannah's (my girlfriend) armory. Separate from the armor itself, this will track the work I've done on the design of her replica and original weapons.

The first project is the lightsaber of her design. So far, I'll be working off of this sketch (click for larger version):
LightsaberWiP3-large.jpg


I'm honestly not sure of what base material I want to use. I have a little experience doing these things with PVC pipe, but I'm not sure that such would be the best choice due to the concave nature of the hilt. Because I'm looking to get into Sintra molding and vacuum forming anyway, I'm wondering if that might be a better way to go about the shell of this design.

I am perfectly fine with doing all of my own research, and will be doing just that, but I would definitely appreciate any advice and recommendations that you may offer.

That being said, has anyone had much luck with vacuum forming or Sintra molding the shell of a lightsaber hilt, or is some other technique superior?

Thanks! Enjoy! :cheers
 
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Kyram

Hunter
If you're going to go the sintra/plastic route you could always start with a PVC plumbing tube as a base. Then you could use peices of sintra and bondo to craft the details.
 

Zannah

Hunter
Thanks for the advice. I really need to finish that drawing...make that skull look better, for one, and figure out how to do that texture on the lower end of it.

Plus, I have more pieces to design. :)
 

Darasuum Verd

Active Hunter
it looks good so far

just make sure to live up to the name, I expect much from someone with a Sithy name ;)

can't wait to see how this ends up!
 

Dessel

New Hunter
Plus, I have more pieces to design. :)

Speaking of which. Here is the first draft of her complimentary lightsaber hilt (click for a larger view):

Saber2WiP-large.jpg


It seems that, with names like Dessel and Zannah, we do have quite the reputation to live up to. But if I'm crafting these things for Zannah, surely I cannot help but create the finest of goods, right? ;)

Thanks for the interest.
 
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Darth Valcar

Active Hunter
Speaking of which. Here is the first draft of her complimentary lightsaber hilt (click for a larger view):

Saber2WiP-large.jpg


It seems that, with names like Dessel and Zannah, we do have quite the reputation to live up to. But if I'm crafting these things for Zannah, surely I cannot help but create the finest of goods, right? ;)

Thanks for the interest.

Looks great will you be making this a lights and sound saber ?
 
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jodo

Well-Known Hunter
I think I would use a peice of PVC as a base, and then build it up from there so it will be easier/study. For the first saber you posted, you may try putting bigger peices of PVC on top of it and then using bondo to build up into them for the slant/coke bottle shape.

For the second saber, you might also try using PVC, if you go to Lowe's,etc. You be able to find some angled peices,etc. thats how I did my old saber. I also used some round soft "things". :lol:
Its also how I did my small explosive device. -


e240610d.jpg
 

Zannah

Hunter
I think I would use a peice of PVC as a base, and then build it up from there so it will be easier/study. For the first saber you posted, you may try putting bigger peices of PVC on top of it and then using bondo to build up into them for the slant/coke bottle shape.

For the second saber, you might also try using PVC, if you go to Lowe's,etc. You be able to find some angled peices,etc. thats how I did my old saber. I also used some round soft "things". :lol:
Its also how I did my small explosive device. -
Thanks for the advice. I don't remember seeing pieces curved like that anywhere, merely corner ones, but I'll have to look. I was thinking of using some sort of foam or something for the grip on the first one, but I'm not certain yet.

Thanks for all the compliments as well. :D Now...hmm...set of blaster pistols and the armor to design. Guess I'll be busy.
 

Dessel

New Hunter
Thanks for all the compliments as well. :D Now...hmm...set of blaster pistols and the armor to design. Guess I'll be busy.

Blaster pistols? Let's see what I can dig up.

Oh, what's that? A new sketch?

Yes, here's Zannah's latest sketch for a blaster pistol:
Pistol1-large.jpg


Does anyone have any recommendations for what to use as a base for this? The near-right angle leads me to think that the NES Zapper won't be a perfect base. Anyway, any recommendations would be appreciated!
 
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Zannah

Hunter
Well, I still need to find some pvc for the lightsabers...there are some dowel things laying around that are about the right size, as well.
 

eighteendelta

Active Hunter
Blaster pistols? Let's see what I can dig up.

Oh, what's that? A new sketch?

Yes, here's Zannah's latest sketch for a blaster pistol:
Pistol1-large.jpg


Does anyone have any recommendations for what to use as a base for this? The near-right angle leads me to think that the NES Zapper won't be a perfect base. Anyway, any recommendations would be appreciated!

Cut it out of fiberboard or hardboard and build it up from there.

-x
 
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Dessel

New Hunter
Cut it out of fiberboard or hardboard and build it up from there.

-x
Sounds like a plan. Thanks. :cheers

I spent a little time working on Zannah's straight/tapered saber hilt earlier. I started by trying to adapt a simple sparring hilt I created previously, but I felt it was too bulky and just not right. I took another, smaller, piece of PVC pipe and worked on building it up from there.

The material I'm using for building this up is a form of the plastic signboard, but this is corrugated, and I don't think that's what I want to be using in the long run. Still, for prototyping, it seems to work.

Here's what I've been able to do so far:
ZannahSabers1-large.jpg


The upper one is, visibly, the larger, bulkier version. It just isn't what I wanted it to be. The bottom one is the sleeker one, and considerably closer to the concept draft.

Though still a ways off from the end goal, some progress has been made. I'm already finding that I enjoy hand crafting these things.

In regards to the curved hilt, forgive my ignorance, does PVC pipe become malleable when heated? I would think this quite possible, but I'm not sure.

Any and all feedback will be appreciated!
 

eighteendelta

Active Hunter
PVC does soften but it also becomes brittle and discolored when heated to reshap, especially at the thickness you are going to find in a PVC pipe. Instead of melting I would suggest using an old welders trick when using straight pipe to build a curved exhaust system. Cut out wedges in even pieces at the same angle like such...

curvedsabre.png


Forgive my poor rendition. Glue the pieces back together and sand it as smooth as you want for this project, it might even be kind of a nice texture if left without smoothing too much. Using a thicker piece of PVC pipe would work better in any case. Good luck.

-x
 
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Dessel

New Hunter
eighteendelta, I've made use of your recommendation. Thanks for taking the time to create illustrations as well!

I used a slight variant of it, actually. I ended up using a series of inch-long segments with a flat side and an angled side. I haven't gotten a chance to go pick up real materials yet, so I'm just making due with my dremel, some PVC I had lying around, and man's best friend - duct tape.

Here is the current build of the curved hilt:
curvedhilt1-large.jpg


Alternate view:
curvedhilt2-large.jpg


I admit, again, I'm pretty new to crating things like this. How would you recommend creating the wedges in your illustration (as in, what tool would you use)? I referenced a dremel, and that's what I used to do this, but it's not really looking like the optimal tool for the job.

Thanks!
 
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eighteendelta

Active Hunter
A bandsaw or scroll saw seem to be the best option in my mind. Don't worry if your edges aren't perfect at first, just cut the wedges, then lay some sandpaper on a hard flat surface and sand your joining surfaces flat. Looks like you got a good start already.

-x
 

Dessel

New Hunter
Thanks for the tip, eighteendelta.

We made some progress on the straight hilt today, so here is what we currently have to show for it:

zannahhiltalpha-large.jpg


Some of the duct tape we were using can be seen, unfortunately, but the overall progress is pleasing. I'm very impressed with this spray paint we found... it doesn't look quite like we're using a metal as the core component, but it's not too terribly far off.
 
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drokkul

Active Hunter
You know...for the curved lightsaber you might be able to get some chrome pipe mandrel bent at a muffler shop. No creases, no seams and you would have it chrome like most all sabers.
 
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