Mandalorian Mercs Costume Club

Mandalorian Armor => Equipment & Accessories => Jetpacks/Backpacks => Topic started by: VikingWagen on Aug 08, 2010, 10:06 PM

Title: styrofoam ftw? now with WIP
Post by: VikingWagen on Aug 08, 2010, 10:06 PM
So I am making a backpack and I have found this perfect piece of Styrofoam but the real question is what can I do to coat the material to prevent the spray paint from eating through it? Anyone?
Title: Re: styrofoam ftw?
Post by: Dar'manda on Aug 08, 2010, 10:23 PM
Thin down some elmers glue with water and use a brush to coat it.
Title: Re: styrofoam ftw?
Post by: Hondo Karr on Aug 08, 2010, 11:07 PM
Use it as a base template but dont use it for the build. Make it out of cardboard and fiberglass it.
Title: Re: styrofoam ftw?
Post by: VikingWagen on Aug 08, 2010, 11:36 PM
its a really thick vacuum form foam for packing, any thought on fiber glassing that? or do you think it'll melt through it as it heats up?
Title: Re: styrofoam ftw?
Post by: Dar'manda on Aug 08, 2010, 11:37 PM
Nosaj is using it for a shield for his son. I've seen it use on verps and the like. Make sure the glue seals well and you sand well too.
Title: Re: styrofoam ftw?
Post by: No'saj Huune on Aug 08, 2010, 11:49 PM
Heres the shield W.I.P. Ijaat mentioned...

http://mandalorianmercs.org/forum/index.php?topic=28500.0
Title: Re: styrofoam ftw?
Post by: VikingWagen on Aug 09, 2010, 12:18 AM
its not exactly the pink foam or craft foam, its like the foam that holds a product in a box to keep it from rattling around mebbe I should take pics? :D
Title: Re: styrofoam ftw?
Post by: Dar'manda on Aug 09, 2010, 12:22 AM
Speaking chemically, they are virtually the same once impregnated with elmers and fiberglassed. Pink foam is just a little tighter packed in the 'cells' of foam, is all. Give it some extra love with the seal and fiberglass treatments and your fine, or you could try to template and recreate in pink foam or cardboard.
Title: Re: styrofoam ftw?
Post by: VikingWagen on Aug 09, 2010, 12:24 AM
sweet! thanks guys I am going to try this out this week I'll post up some WIP
Title: Re: styrofoam ftw?
Post by: No'saj Huune on Aug 09, 2010, 12:42 AM
Just remember when sealing the foam you're going to want to do several layers of the Elmers before the fiberglassing.  If you have one small spot that the fiberglass can seep through it'll melt the entire piece.  Wish ya luck and I look forward to seeing your W.I.P.  ;D
Title: Re: styrofoam ftw?
Post by: Dar'manda on Aug 09, 2010, 02:01 AM
Yes, VERY important about the elmers glue!  ;D
Title: Re: styrofoam ftw?
Post by: Spanner Murraan on Aug 09, 2010, 02:02 PM
The Fiberglass resin alone will eat and melt that styrofoam quick, fast, and in a hurry, and could even pose a fire hazard.  Resin gets very Hot when it is curing, that is why you should only mix it in paper or metal containers.

I would suggest not using styrafoam at all. as A'den suggested, you can use it as a template for cardboard, or plastic.  At the end of the day, Styrafoam will just end up looking like styrafoam (IE- cheap)
Title: Re: styrofoam ftw?
Post by: Dar'manda on Aug 09, 2010, 03:03 PM
Spanner.... I've worked with styrofoam and pink board for years doign 40k terrain. The elmers glue seals it against the fiberglass reacting and melting it and causing any hazards. And once it's covered in fiberglass and sanded, bondo'd, and painted, if it's done right with the proper attention, it won't look any different or worse than anyone who builds something out of carboard and fiberglasses it, or hammers flat sheets of metal or anything.

Styrofoam props tend to look cheap and like crap because, quite frankly, the largest amount of people who use them are looking for a quick way out, and a cheap way out, and don't bother to put in the proper effort and work.
Title: Re: styrofoam ftw?
Post by: twistedxknights on Aug 09, 2010, 03:05 PM
Honestly why not put a layer or two of paper mache or Water Activated Paper Packing Tape then fiberglass? maybe try out the Aqua resin to see if it will work as well..
Title: Re: styrofoam ftw?
Post by: Dar'manda on Aug 09, 2010, 03:10 PM
Strength.. Paper mache will fall out. Aqua resin, as far as I remember, it still an exothermic reaction, and thus will melt. Water activated packing tape could work, but like Nosaj said... You get one gap (easy to do with tape) or soak through (in the case of the tape) and it's all shabs up.
Title: Re: styrofoam ftw?
Post by: Spanner Murraan on Aug 09, 2010, 03:26 PM
If you are going to glass it anyways... why not just make it hollow? at least then it will be lighter, and you can put a camelback in it.  glass a shell, build some light aluminum braces... badda bing.
Title: Re: styrofoam ftw?
Post by: OriKad on Aug 09, 2010, 03:57 PM
If you get the resin set you can cut most of the styrofoam out of it, or if you have a good strong wind, melt the foam out.  Much like  lost-wax casting.
Title: Re: styrofoam ftw?
Post by: Spanner Murraan on Aug 09, 2010, 04:03 PM
If you get the resin set you can cut most of the styrofoam out of it, or if you have a good strong wind, melt the foam out.  Much like  lost-wax casting.

great Idea, Ori.
Title: Re: styrofoam ftw?
Post by: VikingWagen on Aug 09, 2010, 08:15 PM
sweet I can't wait to test some of these ideas out I'll post updates when I begin this week, it makes me pretty happy that when I ask a simple question I can get alot of different examples and ideas to try, much appreciated fellow mandos! ;D
Title: Re: styrofoam ftw?
Post by: No'saj Huune on Aug 11, 2010, 01:43 AM
No worries thats what we're here for.  ;D   However check out my thread tomorrow evening for a surprising result that will help you further.
Title: Re: styrofoam ftw?
Post by: VikingWagen on Aug 23, 2010, 10:52 PM
So I had a breakthrough on the back pack, Kilz sealer is awesome, just a couple of layers seals the foam and allows spray paint with "No Disintegrations" also my brother informed me of a product called Foam lock or Foamlock not sure of spelling that is specificaly meant for hobby styrofoam coating to seal it and allow painting....I know the Kilz works after some preliminary testing,  WIP soon! ;D
Title: Re: styrofoam ftw? now with WIP
Post by: VikingWagen on Aug 27, 2010, 01:10 AM
here is the pics after applying 2 layers of Kilz sealer with some cheap brushes, here are also some components I'm going to be adding

electronics
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0511.jpg)
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0512.jpg)
tubing
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0513.jpg)
innercasing
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0514.jpg)
real fancy doodads
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0515.jpg)
texturing
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0518.jpg)
after doodad addition and 2 layers of kilz
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0524.jpg)
baselayer, notice the absence of pitting of the foam, mission of accomplished!
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0526.jpg)
initial weathering
(http://i994.photobucket.com/albums/af63/johnnycxxx/IMG_0528.jpg)
Title: Re: styrofoam ftw? now with WIP
Post by: Seeker on Aug 30, 2010, 10:11 PM
Lights!!!!!!  I like lights!!!
Title: Re: styrofoam ftw? now with WIP
Post by: VikingWagen on Aug 31, 2010, 02:59 AM
hehe I don't think its going to be together by dragon con 8( but pretty soon I am a big fan of lights!