Mandalorian Mercs Costume Club

Mandalorian Armor => Armor Construction => Topic started by: GraniteDad on May 26, 2020, 11:21 AM

Title: The courier - WIP first build
Post by: GraniteDad on May 26, 2020, 11:21 AM
Howdy folks! I'm making my first set for myself- made two for my girls a few years ago, but time to go for OM. The idea is that this mando is a courier, delivering messages where others won't go. Kinda silly in a universe with galaxy-spanning communications systems, but humor me.  :laugh:

From my concept post- postman blue for the flightsuit, navy blue for the flak vest, then army or hunter green for the armor. Unsure right now on the accent color to use- either a brown, other green, or some wilder color. It'll definitely be matte/flat for the armor vs a gloss finish. The lighter color on the soft parts will definitely make weathering more fun- I definitely want this kit to look lived in vs pristine.

I've decided (for now) to do a loincloth instead of codpiece. I've got a PM out for a helmet, and I've started some work on the armor.

For knees, I'm going to try Bearded Mando's amazing coffee can trick. We'll see how it goes. http://mandalorianmercs.org/forum/index.php?topic=164442.0 (http://mandalorianmercs.org/forum/index.php?topic=164442.0)

For vambraces I'm going to try something and hopefully it'll work. I was at Joann fabrics the other day and saw these cemetery flower holders.
(https://i.imgur.com/tS9RQQF.jpg)

I scraped out the weird stuff in the middle, cut off the bottom 2" and they look OK.
(https://i.imgur.com/nd402YA.jpg)
(https://i.imgur.com/FyPSU8S.jpg)

They do cover more than 2/3 of my forearm so we're good there.
(https://i.imgur.com/Z1elYEn.jpg)

They'll need some stuff on top to look more like functional bracers vs armor, and I may need to cut them down a bit more. But it's a start!

I was thinking of building some sort of rifle, but then realized I had 2 sets of Westar 34s from a few years ago, so felt I needed to work with what I'd already paid for. Rifle coming later, but for now I'm working on how to build a holster out of some leather mag pouches I picked up.
(https://i.imgur.com/vmY9FiB.jpg)
Title: Re: The courier - WIP first build
Post by: Kurz on May 26, 2020, 06:15 PM
Howdy folks! I'm making my first set for myself- made two for my girls a few years ago, but time to go for OM. The idea is that this mando is a courier, delivering messages where others won't go. Kinda silly in a universe with galaxy-spanning communications systems, but humor me.  :laugh:
Well, it's not even that silly if you think about it. In one episode of "Rebels", comms are shut down and the empire uses droids to deliver messages. You might go on a wild planet with no comm infrastructure, or you can deliver death  :laugh:
"the Hutts send their regards". A hitman, code name "the courier".

"They sent a mandalorian to deliver a message, it must be important"
"It is."
*blast*
Title: Re: The courier - WIP first build
Post by: jethroskull on May 26, 2020, 06:32 PM
"the Hutts send their regards". A hitman, code name "the courier".

"They sent a mandalorian to deliver a message, it must be important"
"It is."
*blast*
Yesss!
Title: Re: The courier - WIP first build
Post by: GraniteDad on May 26, 2020, 06:42 PM
"the Hutts send their regards". A hitman, code name "the courier".

"They sent a mandalorian to deliver a message, it must be important"
"It is."
*blast*

Love this! Officially canon for my backstory now  :laugh:
Title: Re: The courier - WIP first build
Post by: REX on May 26, 2020, 07:33 PM
Canít wait to see how you progress with this!
Title: Re: The courier - WIP first build
Post by: Kurz on May 27, 2020, 05:09 PM
Love this! Officially canon for my backstory now  :laugh:

Glad you liked it  :laugh: i think a good back story is as important as a good kit  :laugh:
Title: Re: The courier - WIP first build
Post by: GraniteDad on May 30, 2020, 06:24 PM
Looking for feedback on if these vambraces look long enough. Measurement wise I think they work, but I don't want to spend a bunch of time working these, only for them to not meet specs.

under view
(https://i.imgur.com/ZWIjnpM.jpg)

top view
(https://i.imgur.com/aqMwZHQ.jpg)
Title: Re: The courier - WIP first build
Post by: Kurz on May 30, 2020, 06:40 PM
I'm no app team nor OM, so take what I'm saying just as a personal opinion. Staff members are much more qualified to answer.
First of all, awesome find. I like how they end, it's very peculiar.  :like:
Second, according CRLs
Quote
Full or half/bracer-style hard shell gauntlets that cover at least 2/3 of the length of the forearm from wrist to elbow and at least half of the circumference.
I didn't do the math, but I guess that's more like 1/2 than 2/3 maybe? Not 100% sure.
If I'm right that's an easy fix though. Just glue pipe with a slightly larger diameter on top of the wrist portion or form some sintra and glue it on top.
Title: Re: The courier - WIP first build
Post by: GraniteDad on May 30, 2020, 07:21 PM
I didn't do the math, but I guess that's more like 1/2 than 2/3 maybe? Not 100% sure.
If I'm right that's an easy fix though. Just glue pipe with a slightly larger diameter on top of the wrist portion or form some sintra and glue it on top.

I think you're right - I've been measuring the % based on the inside crook of my elbow, but in re-reading I think the intent might be to the true elbow itself- like where the bones connect. It's fairly snug at the wrist, so I might not be able to add anything there. But I'll play around with it and see what I can figure out.

EDITED TO ADD:
I think I figured out an elegant solution! If I stack them, I still get the flared bit at the end that I like, and it creates a cool effect. I'll have to go get 2 more, but I think this could work.
(https://i.imgur.com/fW7FmF4.jpg)

Then, to stack some greeblies and make this sucker operational! (just some ideas, nothing certain yet).
(https://i.imgur.com/gk3YVoL.jpg)
Title: Re: The courier - WIP first build
Post by: Straka Zulu on May 31, 2020, 11:28 AM
You're headed in the right direction.  That's pretty close to what my first gauntlets were made from: a toilet brush holder.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jun 06, 2020, 11:48 AM
OK, cut out templates, and taped them on. Can I get some thoughts on size overall? I feel like the collar might be too wide- maybe cut some out of the middle? But the tape square on my left shoulder is 2" and that seems roughly aligned with where the shoulder bells should start.

(https://i.imgur.com/4Bm4GyO.jpg)

The painters tape is 1" wide, so this is roughly aligned with where I'd place them, but want to get confirmation on size before I do cardboard versions for better placement. I don't have my flak vest yet, so can't really finalize final placement.

The + sign of tape is on my bellybutton. The armor is not all sideways, my daughter is just not the world's greatest photographer.
(https://i.imgur.com/C3TdQXx.jpg)

(https://i.imgur.com/naWlbC9.jpg)

(https://i.imgur.com/ACie9Zk.jpg)

(https://i.imgur.com/mi9XQLl.jpg)

Title: Re: The courier - WIP first build
Post by: Kurz on Jun 06, 2020, 01:51 PM
I'm no app team, but i'd say everything looks a bit on the large side. Also I think I see a little misplacement on the collar patterns.
(https://i.imgur.com/u8hlE5D.jpg)
Don't know if I was able to explain myself. Those two corners should overlap i guess.
This way the collar should be less side, but I'd go with spalle templates anyway.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jun 06, 2020, 01:55 PM
I'm no app team, but i'd say everything looks a bit on the large side. Also I think I see a little misplacement on the collar patterns.
(https://i.imgur.com/AuaLRmS.jpg)
Don't know if I was able to explain myself. The "underlined" part should be overlapping the same portion on the right.
This way the collar should be less side, but I'd go with spalle templates anyway.

OK, that makes a ton of sense, that explains why the collar felt so wide on me. I can fix that easily.

I can see what you mean about the overall size. I think I'm just so scared of cutting all the plates and having them be too small and having to start over. But if I try smaller for the cardboard cutout, that should help me determine.

Thanks again!
Title: Re: The courier - WIP first build
Post by: Kurshi BeJahaal on Jun 18, 2020, 11:54 PM
Okay! Found this thread and commenting to watch your build!

I'll agree that everything looks a touch on the big side. But bigger is always better than smaller. You can always trim to get it where you need it. :)
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jun 19, 2020, 03:51 PM
I tried the smaller templates and I really think this is the right fit. Do folks agree that these look sized OK? Again, the spacing isn't perfect, but the painters tape is 1" wide, so I feel like it's generally solid.

(https://i.imgur.com/DdAXyjb.jpg)

(https://i.imgur.com/tlfcKd7.jpg)

Title: Re: The courier - WIP first build
Post by: Straka Zulu on Jun 19, 2020, 04:12 PM
You could trim about 1/16" off the outside of the chest templates.  The spacing is pretty close, but with the outer edge of the chest, you would want to hold your arms straight forward, or cross them, and not crinkle the paper too much.

Title: Re: The courier - WIP first build
Post by: GraniteDad on Jun 19, 2020, 04:21 PM
You could trim about 1/16" off the outside of the chest templates.  The spacing is pretty close, but with the outer edge of the chest, you would want to hold your arms straight forward, or cross them, and not crinkle the paper too much.

Awesome, that's very helpful. Makes sense to take that off on the outside only. Thank you!
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jun 24, 2020, 09:14 PM
OK, maybe the lamest armor update ever, but I'm excited! I went to an armor party this weekend, and went from having paper templates to almost all my armor rough cut on sintra!
(https://i.imgur.com/UDW7Sfi.jpg)

Still need to cut out the true armor lines, bevel the edges, check that things look good and sizes are still OK. I kept the armor as printed, so need to take that 1/16" off the outside edges.

Once that's done, it'll be on to my backplate and shaping... and hopefully my helmet will arrive around then.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jun 26, 2020, 02:29 PM
Helmet received. I think the USPS decided to put "Kick the Bucket" to the test. Check out this box:
(https://i.imgur.com/pWPj2a6.jpg)

Luckily, the helmet is as tough as described, and made the journey unscathed!
(https://i.imgur.com/TzPqJKi.jpg)

Can't wait to start finishing this thing.

Also making some slow armor progress, cutting the excess off carefully, and starting some minor beveling. I'm really not good at this, so taking it a slow as I can to avoid costly mistakes.
(https://i.imgur.com/GCBa9nf.jpg)
Title: Re: The courier - WIP first build
Post by: Knight0351 on Jun 26, 2020, 10:57 PM
Helmet received. I think the USPS decided to put "Kick the Bucket" to the test. Check out this box:
(https://i.imgur.com/pWPj2a6.jpg)
Good Lord it is good that the helmet is fine but jeez
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 09, 2020, 09:53 PM
OK. Minor progress tonight, but all the armor pieces are cut out. Started sanding the edges a bit to even them. Lots of work to go!

Iím really excited for three upcoming armor parties: one virtual, and two in person. Really hope thatíll help move things along.
Title: Re: The courier - WIP first build
Post by: Awall on Jul 11, 2020, 02:15 PM
Keep up the progress... no doubt the armor parties will sling shot you even further in the build.
Title: Re: The courier - WIP first build
Post by: Kurshi BeJahaal on Jul 18, 2020, 09:58 PM
I have two of those Kick The Bucket helmets sitting off to the side for future use. I'll be excited to see how yours turns out!
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 18, 2020, 10:35 PM
I have two of those Kick The Bucket helmets sitting off to the side for future use. I'll be excited to see how yours turns out!

Did you get yours pre-assembled? How do you recommend I smooth the seams? Do I need to add a bunch more bondo or can I smooth down whatís there? I was sanding it on the Zoom call tonight but Iím worried about sanding too much and it falling apart. But maybe Iím just overthinking this.
Title: Re: The courier - WIP first build
Post by: Kurshi BeJahaal on Jul 18, 2020, 11:08 PM
Mine did not come assembled. He recommended using a specific PVC glue to hold it together but didn't specify much beyond that.

I haven't assembled mine yet, so I can't give any specific pointers. You can maybe use quiksteel to add some structure to the seams. It not only will cover the seams, it hardens and adds some durability and strength to that seam. It's a bit more difficult to sand, but can really add some integrity to potentially weak spots.

If you can get a few pictures, that would be awesome!
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 19, 2020, 07:53 AM
Here's what I'm working with. The helmet seems very sturdy right now- the seams aren't bendy, so that's good. But just worried about smoothing to take off some of this sealer and that making it less secure. If it's not clear in the photos, I am going to Firaxan's armor party in a week, so can always have someone look at it "live" for pointers as well.

(https://i.imgur.com/KgTs4Tc.jpg)

(https://i.imgur.com/uBWuB9I.jpg)

(https://i.imgur.com/NwWvFIx.jpg)

(https://i.imgur.com/EGhNLm6.jpg)

(https://i.imgur.com/VkXx5gl.jpg)
Title: Re: The courier - WIP first build
Post by: Kurshi BeJahaal on Jul 20, 2020, 12:01 AM
Hmm... It's hard to say. What type of adhesive did you use to hold the dome to the rest of the helmet? If that's a solid bond, you might be alright to sand it down flush.

I think the key is making sure that your initial bond between your dome and sides won't flex too much. The bondo doesn't always do much for strength and can crack if there's a possibility of some movement. It wasn't a bad idea to pause and ask a few questions.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 20, 2020, 07:56 AM
The guy did this initial bond/seal. Iíll check with him- good point that the material makes a huge difference.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 24, 2020, 07:01 PM
Itís bondo professional filler according to the guy. I think that means I can sand smooth and it should still maintain integrity. So thatíll be my new project.

On the negative side, my helmet fans donít work. Looks like they may have gotten damaged in transit. Iím going to fiddle with them and see what I can figure out.

Edit:
Made some progress today while my wife worked on my vest! Sanding with a fine grit is working better than a rough grit, and keeping it wet is helping with dust.

Ready to eat doritos and sand a helmet:
(https://i.imgur.com/s39Ocgw.jpg)

Bondo is pretty rough:
(https://i.imgur.com/JFd8Hyv.jpg)

Made some progress, but forgot to take a closeup, so here's me wearing the vest and staring off into the distance:
(https://i.imgur.com/HzSWCG6.jpg)

Once I'm done, I think I'm going to try hitting it with a primer spray paint that has filler, and that should help smooth things out. It's a beautiful helmet overall, really happy with how it's coming together.

Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 26, 2020, 02:56 PM
More progress today! Worked hard on sanding, and hit the helmet with a really light layer of spray paint w/filler. Hoping that will fill in some imperfections, and make it clear where I need to focus more effort in my sanding.

Helmet work:
(https://i.imgur.com/9yvHl0B.jpg)
(https://i.imgur.com/Nvrkky5.jpg)

Vambraces:
(https://i.imgur.com/uZJ9mAc.jpg)

Also, I'm having a crisis of colors- I went to the hardware store this afternoon, and there is a TON of cool metallic spray paints in a hammered style that looks dope.  What do you think? I am thinking a metallic look with some green or blue stripes/accent pieces instead of the matte army green all over. Or, I could use that hammered look as the undercoat and then paint over it with army green so you only see it in weathering, but I'm worried that'll look too messy.

hammered metallic ideas:
(https://i.imgur.com/exKUetd.jpg)
(https://i.imgur.com/SQGEvKB.jpg)
(https://i.imgur.com/TAoJn9q.jpg)
Title: Re: The courier - WIP first build
Post by: Atiniir Tor on Jul 26, 2020, 03:57 PM
Lookin great vod! I'm partial to the copper and darker grey metals personally.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 26, 2020, 04:02 PM
Lookin great vod! I'm partial to the copper and darker grey metals personally.

Yeah, I may head down to the hardware store with my vest and scrubs and just wander around looking at things. I don't want to buy a bunch of paint that clashes. Just really drawn to the darker grey hammered metal as an idea.
Title: Re: The courier - WIP first build
Post by: jethroskull on Jul 26, 2020, 06:15 PM
I'm planning a hammered copper base with matte sand over it, then a lot of rub-through. I'm thinking it will give a great weathered look.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Jul 26, 2020, 06:18 PM
I'm planning a hammered copper base with matte sand over it, then a lot of rub-through. I'm thinking it will give a great weathered look.

That sounds amazing!
Title: Re: The courier - WIP first build
Post by: GraniteDad on Aug 08, 2020, 09:51 PM
I got some Rustoleum "Forged Hammered" spray paint in Antique Pewter, with an accent color of a chalk texture blue. Spent some time today doing testing on spare sintra pieces I have. Really pleased with the look- it looks very metallic, and the chalk texture in the blue stripes looks dusty and somewhat faded already, so weathering should work well. The big thing I found is that I have to do a base coat with the metallic paint, then the accent color over it. Otherwise the thinner blue paint looks sunken in and flat.

Couple sample shots:
(https://i.imgur.com/qbgbQJL.jpg)
(https://i.imgur.com/2yzuSjN.jpg)

And here's a shot where I applied the chalk blue right onto the white sintra- really looks different and not good at all:
(https://i.imgur.com/MKqMKrz.jpg)

I then rushed to do a quick paint test on my bracers, which was a mistake as now I need to sand a lot off as the surface wasn't smooth enough before I painted and the imperfections really stand out. Blah- hoping I can fix it and don't have to start over there.
Title: Re: The courier - WIP first build
Post by: jethroskull on Aug 09, 2020, 12:01 PM
Chalk texture, eh? Note to self; that has a nice sandblasted look.
Title: Re: The courier - WIP first build
Post by: GraniteDad on Sep 19, 2020, 11:13 AM
Hey guys Iím going to be stepping away from this project for a bit and think about if this is the right thing for me.
Title: Re: The courier - WIP first build
Post by: jethroskull on Sep 19, 2020, 11:58 AM
Hope everything is okay, you seemed to be on a roll. But life...
Title: Re: The courier - WIP first build
Post by: Straka Zulu on Sep 19, 2020, 02:03 PM
Real life comes before plastic spacemen.  We'll be here when/if you decide to come back, but you will still be our vod either way.