Mando Mercs Costume Club

Mandalorian Armor => Armor Construction => Topic started by: Syko Voss on Jun 10, 2015, 09:10 AM

Title: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 10, 2015, 09:10 AM
Welcome to my WIP - it's an ongoing thread and a record of how I built the following male and female kits for myself and my Disney-obsessed wife, Jayne, in just over 12 months and got them passed as official kits in time for Star Wars Celebration 2016.

Both kits, total cost no more than £200GBP to make.  Everything was built from the cheapest raw materials and objects found in the recycling. Only Jayne's under armour, my overalls, boots and the two skate helmets used as a basis for our helmets were purchased.

(http://i.imgur.com/pEFIyma.jpg)

(The mouse ears on Jayne's kit are just for fun and are easily removable!)

To allow me to easily reference my WIP here's a table of bookmarks that I'm building to skip to the relevant sections.


TABLE OF CONTENTS


Note - sometimes a post covers several topics so you may have to scroll down a little to find the exact info you're looking for within the post


JULY 2017 - APOLOGIES FOR BROKEN IMAGE LINKS - CURRENTLY RESTORING THEM AFTER MOVING OVER TO IMGUR FROM PHOTOBUCKET - IF YOU HAVE ANY QUESTIONS, PLEASE PM ME AND I'LL DO MY BEST TO RESTORE THE RELEVANT IMAGES FOR YOU ASAP


Helmet - sizing paper template to head (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1372450#msg1372450)
Helmet - making cardboard form to shape Foamex to helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1373071#msg1373071)
Helmet - shaping Foamex around cardboard form (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1378117#msg1378117)
Helmet - attaching Foamex wrap to skate helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1387690#msg1387690)
Helmet - heat forming cheeks and attaching to mandibles (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1396888#msg1396888)
Helmet - earcap scratch build from BBQ sauce lids (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1404116#msg1404116)
Helmet - earcap body Foamex scratch build and attachment to helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1424957#msg1424957)

Helmet - welding T-visor cutting and attachment to helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1424957#msg1424957)
Helmet - smoked acrylic T-visor cutting (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1781411#msg1781411)

Helmets Version 2.0 - Screen accurate Boba Pepakura/Pasteboard build, mould and casting (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1742656#msg1742656)


Chest Armour - how to trim down to fit (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1481376#msg1481376)
Chest Armour - Boba-style display from an old iPod (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1501113#msg1501113)
Chest Armour (female) - darted chest plates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1541616#msg1541616)

Gauntlets - how to build forming jigs using WoF templates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1517273#msg1517273)
Gauntlets - scratch build from WoF heat-forming over cardboard jigs (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1436883#msg1436883)
Gauntlets - Digital Photo Frame installation (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1447131#msg1447131)
Gauntlets - LED lights for longer lasting 'scanner' upgrade (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1669340#msg1669340)
Gauntlets (female) - scratchbuild from WoF heat-forming over cardboard jigs (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1448398#msg1448398)
Gauntlets - scratch build missile from chop stick & PVC pipe (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1456760#msg1456760)
Gauntlets - simulated paint damage using masking fluid, hairspray and rock salt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1524139#msg1524139)

Knees - scratch build using WoF templates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1458580#msg1458580)
Knees - heat forming tips & using cardboard jigs (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1458978#msg1458978)
Knees - assembly and shaping side blocks (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Knees - strengthening WoF knees with PVC strips (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1476357#msg1476357)
Knees - simulated paint damage using masking fluid, hairspray and rock salt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1527334#msg1527334)
Knees - attaching with sleeved elastic strapping (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1537696#msg1537696)
Knees - upgrade - Velcro + strapping adjustment for more comfort (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1738018)

Cod Plate - from WoF template (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Cod & Kidney Plates - attaching using snaps and an old webbing belt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1496116#msg1496116)

Shoulder Bells - from WoF template and how to heat form (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Shoulder Pauldrons (female) - bulking out shoulders to balance a larger helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1555606#msg1555606)

Boots - UK supplier (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1425906#msg1425906)
Boots - armour attachment (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1509867#msg1509867)

Ammo Belt - cardboard forms for Ammo Pouches + Template Files (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1447131#msg1447131)
Ammo Belt - magnetic closures and wrapping with pleather (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Ammo Belt - flaps (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1476357#msg1476357)
Ammo Belt - belt from old belt, cereal box card & pleather (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1480157#msg1480157)

Girth Belt - sewing smaller strips of paracord before combining them into a full belt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1509867#msg1509867)
Girth Belt - using paracord, card, gaffer tape and pleather (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1519140#msg1519140)

Flak Vest (male) - making with own template (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1480157#msg1480157)
Flak Vest (female) - making with own template, chest darts (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1536885#msg1536885)

Flight Suit - simulating grime and dirt with acrylic paints (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1580247#msg1580247)

Rifle Sling - using a 3-point sling to make carrying carbine-style weapons easier (http://mandalorianmercs.org/forum/index.php?topic=95388.msg1612324#msg1612324)

Sanding Tips

Sanding tips - wet & dry sanding and using different grits (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1404116#msg1404116)

Heat Forming Tips
Heat forming tips and using cardboard jigs - quick and easy way to get perfect curves (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1458978#msg1458978)
Cardboard jigs - how to make them fast (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Using aluminium foil & heat to create convincing physical damage (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1491864#msg1491864)
How to "Roll" the edges of armour plates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1526620#msg1526620)

Using Snaps
How to attach plates using Snaps...and still make adjustments afterwards! (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1536946#msg1536946)

Painting Tips
Masking straight lines over curved surfaces using an elastic band (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1572300#msg1572300)
Simulated paint weathering techniques using masking fluid and rock salt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1578642#msg1578642)
Using scrunched Aluminium Foil for masking removal (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1703309#msg1703309)
Espresso coffee use as an effective dirt wash (http://mandalorianmercs.org/forum/index.php?topic=100143.0)
Using Aluminium Tape to make things look like real metal (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1703309#msg1703309)

Weapons

Build Log: 1313 Inspired Blaster Carbine using Foamex, MDF & PVC Pipe (http://mandalorianmercs.org/forum/index.php?topic=95388.0)
(http://i.imgur.com/Jqqe4ll.jpg)

Build Log: Twin Westars from WoF templates using Foamex, MDF & PVC Pipe (http://mandalorianmercs.org/forum/index.php?topic=94201.0)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_3879_zps8fdn1dmk.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3879_zps8fdn1dmk.jpg.html)

Build Log: Kal Dagger build using Foamex & PVC Pipe with downloadable template (http://mandalorianmercs.org/forum/index.php?topic=100143.0)
(http://i725.photobucket.com/albums/ww258/simorph/Kal%20Dagger/IMG_3883_zpsnvjp7ilt.jpg) (http://s725.photobucket.com/user/simorph/media/Kal%20Dagger/IMG_3883_zpsnvjp7ilt.jpg.html)

Build Log: Sidearm Scratchbuild using MDF & PVC Pipe (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1669340#msg1669340)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_0918_zpsss0e4igz.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0918_zpsss0e4igz.jpg.html)

Build Log: Vibrosword Scratchbuild using MDF, PVC rods & Aluminium Tape (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1693448#msg1693448)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_1022_zpsbmhou2tv.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_1022_zpsbmhou2tv.jpg.html)




And here's the start of the thread as it was when I first posted to it on Jun 10, 2015, 02:10 PM  :





Jayne & I have been discussing colours - she really likes the idea of a Zam Wesell palette of purples, greens and golds and wants to go for black form-fitting underarmour gear as her bodysuit to keep things feminine.

I on the other hand, have been thinking much more down-and-dirty for my gear, and having studied a lot of Star Wars reference decided to work with all those earth tones you see throughout the movies, especially on the bounty hunters in Ep V.

To that end, I've already purchased a flight suit - an Armoured Fighting Vehicle coverall and using that as a base:
(http://i.ebayimg.com/22/!BVsMY(wB2k~$(KGrHgoOKi4EjlLm,WWnBKT0nH)fCQ~~_12.JPG)
 (http://www.ebay.co.uk/itm/Army-Surplus-ARMOURED-FIGHTING-VEHICLE-COVERALL-Medium/270420621597?_trksid=p3693.c100102.m2452&_trkparms=ao%3D1%26asc%3D20140212121249%26meid%3Dac060046a2914f5e86f584a4a6bcd53a%26pid%3D100102%26)
It cost me £15 GBP + postage and arrived brand new, fit great and has plenty of 'real world details' that mostly will be covered with armour pieces but should give it more interest than making my own gear.

There are some cool pockets on the front of both thighs and shins that I may have to remove, but I'll make that decision as we move ahead - but certainly comparing it to the movie Boba flight it feels pretty close to me.

That done, I've nabbed the outlines from the online resources and set about with Photoshop to come up with these two designs (I used Photoshop because it allowed me to drop a suggestion of the amount of weathering as well as smaller details on the helmet. etc):

(http://i.imgur.com/mV5r5wy.jpg)

Trying to come up with something that will incorporate some of the purples and greens that will appear on Jayne's gear but will give me the kind of functional, heavily weathered Boba Fett bounty hunter feel that wouldn't look out of place walking through the background of Mos Eisley in any of the movies - just enough customisation and differences in colour to get the look, but steering away from something that looks too outlandish or ceremonial.

Currently pondering whether to go for longer armour plated riding boots, or smaller armoured boots like Jango with additional cloth spats at the ankles to reign in the bottom of the flight suit (as they do on the Boba suit) but cover the boot tops/ankles.

Going for skate helmet-based builds for the buckets - will start building a cardboard mockup/template to test before I start cutting the real Foamex(Sintra) ones.

Thoughts/advice/preferences/suggestions anyone?

Thanks

Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 10, 2015, 06:39 PM
Personally, I like the design on the right a little better.  But they're both solid, good-looking concepts.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 11, 2015, 04:44 AM
I agree.  Thanks
Going to zoom in next and work out if I can add an overpainted design - something that will add to the armour and give it more depth without making it look too garish/ceremonial.

In other news...

HELMET HAS BEGUN

Pleased to say that last night I started on the helmet build using the Foamex (Sintra) wrapped around a skate helmet method.
Printed out the WoF A4 template at 1:1 scale on paper and began cutting.

Tried two sizes of helmet - a very large one we already had at home but seems like the smaller of the two (Large (http://www.amazon.co.uk/gp/product/B00HF80H9O (http://www.amazon.co.uk/gp/product/B00HF80H9O) 57-59cm helmet) matches the dome of the WoF template best (which I'm assuming is scaled to be a 'standard Boba size')

I then attacked the helmet and removed a good hunk of the protective foam from inside of it - which allowed me to lower the helmet a good 0.5".

Wrapping the WoF around the helmet at standard size I found that I have an extra 7.5cm/3" gap at the back since the skate helmet dome slightly widens at the back.

So the next stage is to scale up the WoF templates by 10% which should close up the gap at the back and also make the helmet that little bit taller since with the standard size my chin is visible below the line of the helmet.

I'll post pics of progress so I can get a size check once I get something I think I'm happy with.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 11, 2015, 05:21 PM
So, first step was to get a very fast prototype together just for size - take the WoF template, assemble it in paper and wrap it around the skate helmet.

I found that at 100% the circumference of the helmet was about 7cm too big and my chin and back of neck were easily visible in profile/from the back view.  And that was after removing the foam from inside the top of the helmet so my head would fit higher in the dome.

So here's the results of the 111% quick test - time to build a sturdier cardboard prototype that'll take me a step further to solving how to build this in Foamex (Sintra)

(http://i.imgur.com/4gKmY2e.jpg)

(Aware that the fact that the paper is simply taped to the helmet the profiles aren't correct - this was simply a sizing test - the card prototype will tell me if I can get the shape correct)


Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 11, 2015, 06:30 PM
Overall the sizing seems, to me, to be pretty good.  Although from the back, I can't tell if it's the way you're standing, or the way the paper is taped up, but it seems to wrapping around higher over your right shoulder.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 12, 2015, 01:44 AM
I think that's me failing at standing, facing a wall with a paper bucket on my head  ;D
The card version is in progress and is holding its shape already much better
Thanks!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 12, 2015, 03:55 AM
I think that's me failing at standing, facing a wall with a paper bucket on my head  ;D
The card version is in progress and is holding its shape already much better
Thanks!

This provided a much-needed laugh.  Thanks! 

And I'm looking forward to seeing both your kits come together.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 12, 2015, 04:39 PM
Sizing done, I created cardboard versions of the templates and wrapped the inner section of the helmet around the skate helmet.

A quick wear test showed that the card fared better shape-wise than the paper (naturally) and so that being done, I've turned the whole thing into a solid form that I can wrap Foamex (Sintra) around knowing that it will be only a small bend to fit to the skate helmet when the card is taken away.

Was pleasantly surprised that the WoF bottom template fit perfectly the base of the helmet, so while the skate helmet determines the roundness of helmet at the top, the bottom matches the WoF spot-on. (Phew!)

I reinforced the inside of the card warp with back-to-front and left-to-right supports so that the skate helmet is held in place - I now have a solid form to work with - I intend to form the PVC wraps for both helmets at the same time, then remove all the card and build the two simultaneously:

(http://i.imgur.com/RCgAwAU.jpg)


Since I have plenty of A4 & A3 sheets of Foamex ready for the armour, I've decided to order a single 1mx1m sheet for the four wraps for the two helmets - so each wrap can be a single piece of Foamex and therefore be stronger and I'll have less joins to contend with.

Now to wait patiently for the arrival of the big Foamex board while I spent the weekend planning next steps and eyeing up every object I see on tomorrow's shopping trip for potential repurposing as greeblies or a bounty hunting weaponry...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 12, 2015, 05:25 PM
Nice.  Good work, vod.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Jun 12, 2015, 06:27 PM
Nice work m8, self made lid I take my hat off to you and look forward to seeing progress, design wise I'm more of the left hand side  with the rights helmet detailing
Title: Re: Armour Planning & WIP for 2 of us
Post by: Korran Orainn on Jun 13, 2015, 05:32 PM
Excellent work Vod, massive respect for making a Buy'ce from scratch! :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 14, 2015, 01:18 PM
Thanks guys!

Had a momentary panic when I realised that in printing out the templates scaled and on our crazy UK-sized A4 paper that I'd accidentally used the dome base rather than the helmet base for the shape of the bottom of the bucket.  Thankfully because everything was in card, it was easy to switch in the proper helmet base - which is circular, rather than the oval/egg shape of the dome and now the form has a much better flare at the sides...

So pleased that the Foamex (Sintra) is still on its way to us - I believe in "Measure twice, Cut once" anyway, but on this project, I think it's going to be "Measure twice, Cut once, Build it in card first, Think about it and only then Attempt it in Sintra!"

Spent rest of this Sunday afternoon testing out new tools and while we're still in discussion about the finer details of her gear, we did agree that something like a Jango-style WESTAR-34 blaster is going to be her weapon of choice, so I quickly printed an image from Google at what appeared to be the right size, slapped it on some card and cut it out to check it would fit in her hands.  (I later found the WoF blaster templates : http://www.thedentedhelmet.com/attachments/f28/jango-westar-blaster-blueprints-completed-jango-fett-blaster-rev-pdf-73057d1385267782 (http://www.thedentedhelmet.com/attachments/f28/jango-westar-blaster-blueprints-completed-jango-fett-blaster-rev-pdf-73057d1385267782) and discovered that my size guesstimate was pretty much exact.)  Planning to cut the handle out of MDF and make the barrel and other pieces from Sintra/PVC piping.

Am also doing some prep-work on gauntlets too - figuring that between the helmets, weapons and gauntlets there's plenty to get my teeth into before we source material for flak jackets, tailor those and start on the armour itself.

Clearly the enthusiasm is building here in the household, Jayne tweeted this pic (https://twitter.com/JaynePhipps/status/610106123299987456) of me getting to grips with how to set up the rotary tool I bought last week (an item I've always wanted, but until now never had a project that justified it.)

The revised bucket is in the bottom left of the image, ready and waiting to be wrapped in metres of Sintra...

(https://pbs.twimg.com/media/CHeISVnWoAE3Ih9.jpg)

Hope you've all had a great weekend!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Jun 14, 2015, 01:40 PM
I look forward to watching your progress as a fellow UK vod
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 14, 2015, 02:03 PM
It's great to see you're getting some solid work done, vod. 

Quote
how to set up the rotary tool I bought last week (an item I've always wanted, but until now never had a project that justified it.)

I'm still bouncing a little in glee that I was able to get one for myself recently.  I've used the sanding head to really good effect so far, and plan on experimenting today with the cutting discs I found buried in the attachment kit I bought to go with it. 

I'm eager to see your helmets evolve, and definitely want to see how the Westar 34 turns out.

Keep up the great work, buddy!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Jorad Werde on Jun 14, 2015, 04:58 PM
New toys are always fun aren't they?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 15, 2015, 05:35 AM
Absolutely.
Plus after about 30 years of modelling in the computer it's nice to go back to kit-bashing and physical work - a trip to the garage and the box full of weird and useless spare parts that we've kept for over a decade since we installed the kitchen has given us a stack full of useful greeblies!
Pleased to meet you guys!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 16, 2015, 07:15 PM
Have had a chance to play with the new toys, as I've started scratchbuilding blasters:

WIP Twin Scratchbuilt Westar 34s (first blaster build!) (http://mandalorianmercs.org/forum/index.php?topic=94201.0)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 22, 2015, 06:21 PM
Building the helmets has begun using 5mm Foamex (Sintra) - purchased 1mx1m sheet so I could wrap around the helmet in one piece:

Lots of fun with a heatgun and the assistance of Nikjay (http://mandalorianmercs.org/forum/index.php?action=profile;u=29337) made bending the foam around the cardboard form relatively simple.

(http://i.imgur.com/Rc13iOM.jpg)


Glad there were two of us working on it - one working the heat, the other slowly bending, forming and holding - I'd have hated to have had to try this solo.  (Although there is the risk of getting Tweeted while you're doing it! (https://twitter.com/JaynePhipps/status/612735516530884612))

(http://i.imgur.com/tKwIR1H.jpg)

The result - we now have two 5mm thick inner and outer layers - time to work out all the other parts and get them cut before we start to bolt things together...

(http://i.imgur.com/upNcoXz.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Korran Orainn on Jun 22, 2015, 06:43 PM
Excellent progress! Eagerly awaiting the next update! (are you sure you haven't done this before?)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 22, 2015, 11:04 PM
Watching eagerly, my UK friends.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Jun 29, 2015, 08:03 AM
Great start on the buckets, can't wait to see more  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 09, 2015, 05:18 PM
So we attacked the helmets at the weekend and found that the best way to secure the Foamex (Sintra) to the skate helmets was with 6 small bolts.  The method allowed us to 'pin' the wrap at the front of the helmets, then heat-form the sides, pin those, then heat-form the back.  It meant that we weren't having to wrangle lengths of wobbly Foamex and when it came to matching up at the back of the helmet, we could shave thin strips away until we got a reasonably seamless fit.

(http://i.imgur.com/tihDTt4.jpg)

Some two-part Epoxy glue at the back sealed everything tight...

(http://i.imgur.com/pZXwPPn.jpg)

Then came the wrapping of the helmet with the raised outer section...

(http://i.imgur.com/9NmPjZ3.jpg)

This was pretty trivial and we secured it by slathering with 2-part epoxy and holding it on together until the glue set.  (Definitely easier with two pairs of hands.)

Time to try on and...well, I wasn't happy...    :(

(http://i.imgur.com/TnTcrLx.jpg)

Things just didn't feel right - the 6mm thickness of the outer wrap was making the raised sections stand way too proud for my liking and since we'd aligned the bottom of the outer wrap with the bottom of the inner wrap we were losing quite a lot of the skate helmet dome - too much face, not enough dome.

Despite the epoxy having set (but not yet cured) I managed to rip off the outer wrap and clean off the glue.

A new attack - make a new outer wrap with 3mm Foamex and position it so the top of it lined up with the top of the inner wrap...

The result - a much better, much more balanced helmet:

(http://i.imgur.com/FCzWAEe.jpg)

(To accomodate the skate helmet's shape we had to scale up the WoF template to 111% so I'm very conscious that we don't want these helmets to look too bulky.  But I do recommend 6mm Foamex for the inner wrap - with the skate helmet in place, this really feels like it could take a serious knock!)

(http://i.imgur.com/mzmrXdJ.jpg)

And on the inside I stripped off the excess bolts with the Dremel, covered the remainder with hot glue and then heated up small rectangles of Foamex with the heat gun, pressed them into the holes in the skate helmet, securing them with hot glue.


Next - finish off helmet #2 when we replenish our stocks of 3mm Foamex and then do all the stuff like cut the cheeks, build the ear caps, etc.


IN OTHER NEWS...
Nikjay's Twin Westars  (http://mandalorianmercs.org/forum/index.php?topic=94201.0) are ready for painting...
(http://i.imgur.com/VJJSgBH.jpg)

I've kicked off a new Scratchbuild thread (http://mandalorianmercs.org/forum/index.php?topic=95388.0) as I make a start on my 1313 Inspired Carbine

And finally, as much as I love the flight suit, the more we look at it, the baggier it looks, and the amount of work that will take to tailor it to fit will be pretty hardcore.  So, I've ordered some much more tailored standard coveralls - no khakis available that we could find, so I've opted for 'Graphite' - which means I think I'm going to have to rethink colours - go more urban greys and perhaps a splash of red...










Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jul 09, 2015, 05:22 PM
I love watching your progress, guys.  It's inspiring.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Catika on Jul 10, 2015, 11:28 AM
What a bummer about the flightsuits! I'm sure the graphite will still look cool. Honestly I think the previous color scheme would transfer pretty well to a grey flightsuit?

The helmet looks GREAT! Looks like it'll be really solid.

Meanwhile, I will be over here drooling over those Westars.  :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Welkin on Jul 10, 2015, 12:52 PM
Definitely some awesome work going on in here. Your current color scheme should work with a grey flightsuit, of course you could always try bleaching/dyeing it to a more appropriate color as well.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jul 10, 2015, 03:07 PM
I saw "New" next to this thread and nearly started salivating, hoping for a new update.  (I didn't bother to check that the newest post was by The Mandler. Doh!) 

So I'll check back later, hoping for new updates by Si.   ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Welkin on Jul 10, 2015, 03:26 PM
Hey I wasn't the only one! Plus you can't always go by "newest post" I've made that mistake before and missed out on some awesomeness for a long time (that was in a different group though)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 26, 2015, 04:15 PM
Pleased to say that the 1313-inspired blaster is coming along nicely (http://mandalorianmercs.org/forum/index.php?topic=95388.msg1396877#msg1396877)...(update on this thread (http://mandalorianmercs.org/forum/index.php?topic=95388.msg1396877#msg1396877))

(http://i.imgur.com/xm9Jw0Q.jpg)

And in other news work on the helmets has also picked up some pace...



I cut out the cheek spaces on the helmets...

(http://i.imgur.com/NXLLzyI.jpg)

And in a bit of spare time attacked the key slot inserts - getting them prepped for later...

(http://i.imgur.com/Z2IKmmz.jpg)

And with the help of my fabulous assistant, we took on the task of putting together the mandibles/cheeks...

(http://i.imgur.com/2YZmUM3.jpg)

We found that this was much easier as a two-person job - switching between heat guns and forming the Foamex (Sintra!), looking the curves from many directions and making sure everything was heading in the right direction was far simpler with an extra pair of hands and eyes.

With experimentation we discovered the best way to form the Mandible curves was to hot glue the ear cap side in loosely and then work on forming the rest of the curve with the heat gun - we found it tricky to both keep the piece held in place and form it at the same time...

(http://i.imgur.com/923KxLb.jpg)

With the curve in, lots of hot glue and bit of bodge work got the cheeks in...

(http://i.imgur.com/3gDriIa.jpg)

(Note the fact that I had to cut into the skate helmet a little to clear the visor - a Dremel router bit made short work of that!)

Putting in the cheeks we found it difficult to get them in absolutely geometrically perfect, but they were pretty close and we found that we could create a bit more wiggle room for ourselves when inserting the cheek pieces by using the heat gun to make the in-place mandibles a bit more flexible.

So next step is to finish off applying filler to the cheek/mandible area, do a lot of sanding and then get the key slots in...

(http://i.imgur.com/ByJkG9b.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Jul 26, 2015, 04:31 PM
Very nice work as usual  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jul 26, 2015, 04:49 PM
So awesome.  Good to hear from you guys again.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 26, 2015, 06:44 PM
Thanks guys
Quick question, Reyn (since I see you're on the App Team) are there any things I need to keep an eye on when it comes to building/designing ear caps?

I'm thinking for ease of transport, ease of building that we'd like to build ear caps with antennae rather than building range finders.

Not planning on building anything too outlandish or outside of the 70s/80s Star Wars aesthetic - but before I launch into this I think it's worth asking - is it okay to have equal height ear caps on either side of the helmet (take down the height of the range finder ear cap so it's the same height as the opposite side)?

For my helmet at least I'm thinking of going for antennae on either side of the helmet a little like the Pre-Vizla helmet but constructed around ear caps based on the detailing of Boba's right ear. For Jayne's we'll either do a similar thing or build ear caps like Boba and put in a single antenna in place of the range finder.

I'll post pics before I glue the things on, but any heads up/advice before I start chopping up foam would be real appreciated.

Thanks again!

 Are there any approved examples of this Boba-era style you can point me to?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Jul 26, 2015, 08:30 PM
Earcaps are totally open to customization as are RF's as they are not a requirement unless you are making a canon or brigade build.
I'll shoot you a PM later  ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Welkin on Jul 27, 2015, 11:20 AM
Looks like everything is coming along awesomely so far.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Aug 05, 2015, 06:05 AM
Can I ask, are you reinforcing the inside of the helmet with anything or just leaving the foamex? I ask as I only have 3mm foamex and see you used the 6mm.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 05, 2015, 08:53 AM
Just using the Foamex - the 6mm worked for us for the body, but we had to use 3mm for the outside wrap since a second layer of 6mm made them look far too bulky.

I guess the best way to do it would be to build a two-layer 3mm helmet around the cardboard form first, then if it feels a little flimsy after you've assembled the cheeks, mandibles and keyslot in the back you could then consider putting in a 3mm wrap inside the back to help give it more strength.

But you might not need it.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Aug 05, 2015, 09:54 AM
Just using the Foamex - the 6mm worked for us for the body, but we had to use 3mm for the outside wrap since a second layer of 6mm made them look far too bulky.

I guess the best way to do it would be to build a two-layer 3mm helmet around the cardboard form first, then if it feels a little flimsy after you've assembled the cheeks, mandibles and keyslot in the back you could then consider putting in a 3mm wrap inside the back to help give it more strength.

But you might not need it.

Thank you! Great tips you give :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: crutchthecrusher on Aug 05, 2015, 01:37 PM
looking good so far
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 07, 2015, 01:01 PM
Once again, thanks everyone.

Here's another update...

With the cheeks in I filled all the holes, dents, creases and places where the mandibles didn't quite curve as they should with P38 (Bondo).

Then it was a round of 80 grit sandpaper to rip through the excess followed by time over the sink with 600 grit wet and dry to take everything to smooth...

(http://i.imgur.com/WL2vFGG.jpg)

...and then hitting the helmets with their first round of grey primer.

In addition to making it really easy to see the imperfections, this was a real boost to see - the first time these things looked like objects in their own right not just a skate helmet with some plastic and hot glue stuck to it.

(http://i.imgur.com/GjTpbZv.jpg)

We admired them for a whole five minutes before attacking with P38 (Bondo) to fill in all the pits and dents, and doing a lot of work on the mandibles - building out the right side curve on one of them and bringing the lines of the mandibles out to where they looked right, correcting for the bodging we did when heat forming.

With that done, I took a headlong dash at both the helmets using all the grits - 80 grit, 240 grit with the mouse sander, 600 grit wet and dry and finally (just because I could) 2000 grit to make the helmets smooth as glass...

(http://i.imgur.com/pjBfYUM.jpg)

They're now sitting quietly waiting for the next development - the ear caps.

Plan for the helmets is to build a set of double antennae on my helmet and a single antenna on the right cap for Jayne's helmets - we figure we can do a much better job making those than a half-assed attempt at making range finders....

So I had an idea.

I've been keeping all manner of spare parts from the trash and I realised that the top of a barbeque sauce bottle is the exact diameter of the WoF template ear caps at the 111% we've scale the helmets to...

...so with a pen barrel, a plastic chopstick and a small transparent ring piece from a hand santiser bottle...

(http://i.imgur.com/KqO1NhU.jpg)

...the perfect top of an ear cap!

(http://i.imgur.com/CA68J1e.jpg)

All I have to do now is construct the lower parts of the ear caps and our household has to get through another three bottles of barbecue sauce... (a feat I think our carnivorous family is more than up for!)

In other news, the 1313 inspired carbine is really moving along (http://mandalorianmercs.org/forum/index.php?topic=95388.15#lastPost)...

(http://i.imgur.com/WFyTrDI.jpg)

...And Jayne has finally gotten herself black tight-fitting sports gear for her under armour and  secured us 5m of black faux leather, some industrial needles and thread to hopefully make a start on our flak jackets soon.






Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Aug 07, 2015, 01:12 PM
loving the work and so glad to see im not the only one using bottle tops,etc ...nice ear cap so simple but effective
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 07, 2015, 01:42 PM
Thanks - I'm taking great delight in repurposing everyday objects - once you take them out of context it's a joy to see them become something else - and in fact, that's the spirit of the original trilogy props all over.

When it comes to curves and circular objects, nothing beats machine parts, so if you can find it somewhere in the house, I'll take it and disguise it over trying to cut it by hand.

Particularly pleased with the way the 1313 sight came out (breakdown of what it's made of on that thread (http://mandalorianmercs.org/forum/index.php?topic=95388.15#lastPost)....and yes, it's a lot of bottle caps!)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Aug 07, 2015, 02:00 PM
Mate, this is just sick!  You guys are doing wonderfully with your kits.  I'm in awe of your skills.
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Aug 07, 2015, 03:11 PM
your work output, attention to detail and creative use of found objects is inspirational. will be looking out for you at celebration so I can say hello.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Jorad Werde on Aug 07, 2015, 04:23 PM
Looks like you've got a lot of good work happening.  Great job on that carbine
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 15, 2015, 11:29 AM
Thanks guys - I really appreciate your kind words of support - I wish there was a 'Like' button so I could give you a thumbs-up on your posts!

Pleased to say that Jayne ("Nikjay Voss") and I have finally gotten our act together and pulled together a colour scheme.

Jayne's plan is to use black sportswear as under armour, as I posted earlier I've moved over to a tighter, grey boiler suit.  We now have black faux leather and are about to draw up patterns for our flak jackets.

We've been looking at Kobra Paint (http://kobrapaint.co.uk/page4.htm) for our colours since Jayne was very particular about getting the right reddish purple and green combo, and since we're both aiming to create looks that are 100% in-keeping with something that could have walked off the set of Empire Strikes Back or Return of the Jedi, we're using the following as our base...

(http://i.imgur.com/j0rPEl0.jpg)

We're expecting to heavily weather the armour, so expect a lot of exposed metal.  Unsure of what additional markings to go for yet - as I say, we want something that feels 'in Universe' so we'll be erring on the low key side of things.

In other news, so happy to finally say that the carbine is now ready for assembly...

(http://i.imgur.com/pQvXFIg.jpg)

Update on all the details of this and how Heinz Ketchup bottles have added to its awesome are in this post (http://mandalorianmercs.org/forum/index.php?topic=95388.15#lastPost)...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Aug 15, 2015, 08:50 PM
Loving the colors, vod. Just loving it.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Aug 15, 2015, 09:10 PM
Great use of materials vod! Love the colours and the overall concept. Looking forward to more updates.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Welkin on Aug 16, 2015, 02:14 AM
Looks Excellent!

Can't wait to see that thing fully assembled!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 21, 2015, 05:11 PM
Lots happening this week...


(Post from the future...)
In the end, the kit looked like this....

(http://i.imgur.com/hLIZe5C.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Aug 21, 2015, 07:33 PM
My two favorites are C and G, with C being my absolute favorite.

Love seeing updates from you, vod.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Aug 22, 2015, 02:22 AM
C & J for me but agree with Havelock, loving C.

What did you use to draw those images? Looks great
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 22, 2015, 03:09 AM
Thanks guys! Just Photoshop - I grabbed a screenshot from Mando Maker, went in and tweaked the colours to match the ones fr the spray paint site. I then added another layer and sprayed over a light blast of black to simulate dirt and loaded up another layer into which I pasted in a pic of some brushed metal, hid it with a layer mask and then scribbled onto the mask where I wanted the metal texture to show through.

If you don't have access to Photoshop I can recommend 3 free alternatives - in order of ease of use: Paint.NET (http://www.getpaint.net/index.html), GIMP (http://www.gimp.org) and Krita (https://krita.org) - they're all really good and although I use Photoshop a lot because I use it a lot in my job all 3 are great art packages that I've use to make full digital paintings with.

Thanks for the suggestions there - most helpful!

Have a good one!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Aug 22, 2015, 01:25 PM
Thanks guys! Just Photoshop - I grabbed a screenshot from Mando Maker, went in and tweaked the colours to match the ones fr the spray paint site. I then added another layer and sprayed over a light blast of black to simulate dirt and loaded up another layer into which I pasted in a pic of some brushed metal, hid it with a layer mask and then scribbled onto the mask where I wanted the metal texture to show through.

If you don't have access to Photoshop I can recommend 3 free alternatives - in order of ease of use: Paint.NET (http://www.getpaint.net/index.html), GIMP (http://www.gimp.org) and Krita (https://krita.org) - they're all really good and although I use Photoshop a lot because I use it a lot in my job all 3 are great art packages that I've use to make full digital paintings with.

Thanks for the suggestions there - most helpful!

Have a good one!

Thank you! Have PS so will play around
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 22, 2015, 02:55 PM
Cool - well, if you know Photoshop then, to save you some work and get you rolling...

Here's a Dropbox link to my PSD file (https://www.dropbox.com/s/4am6cuq4fw7xj7n/Male%20Mando%20colour%20tests.psd?dl=0) (just uploading so give it a few minutes to get up there...)

Enjoy and let me know what schemes you come up with.

Mmmm... variant C....  Might have to, y'know

Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Aug 22, 2015, 04:22 PM
Cool - well, if you know Photoshop then, to save you some work and get you rolling...

Here's a Dropbox link to my PSD file (https://www.dropbox.com/s/4am6cuq4fw7xj7n/Male%20Mando%20colour%20tests.psd?dl=0) (just uploading so give it a few minutes to get up there...)

Enjoy and let me know what schemes you come up with.

Mmmm... variant C....  Might have to, y'know

You are the man! Downloaded  ;D

Time to play :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Welkin on Aug 28, 2015, 02:39 PM
I'm really digging all of them, but I may have to buck the trend and possibly lean towards G or E
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 31, 2015, 04:57 PM
Decisions, decisions!

...well, I can still build plenty without having to make a final call just yet.

In our update - my flightsuit now fits thanks to Jayne (Nikjay)'s work with the sewing machine and is CRL compliant inasmuch as it has been stripped of any external pockets!

Big news from my side of things - our first complete prop is finished - the 1313-inspired blaster carbine for my kit (http://mandalorianmercs.org/forum/index.php?topic=95388.45#lastPost).

(http://i.imgur.com/Jqqe4ll.jpg)

Quite pleased with how it turned out. (More pics in the blaster thread (http://mandalorianmercs.org/forum/index.php?topic=95388.45#lastPost).)

Now onto finishing off my other half's Twin Westars, the dagger, the hand armour pieces, earcaps for the helmets and likely making a start on the gauntlets...

(Pant! Pant! Surely 'oversized Jawas' would have been less work for Celebration next year...)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Aug 31, 2015, 05:06 PM
That blaster looks ace.

Paint schemewise, I like bits from each of them. I didnt finalise my scheme till I had the plates taped onto me so I could see what would show etc.

And the Jawa idea would have worked until you were rounded up and the Mandalorians started discussing how much they could get for oversized jawas.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Aug 31, 2015, 11:23 PM
Phenomenal, my friend.  Can't wait to see how your commo earcaps come out.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Korran Orainn on Sep 01, 2015, 10:48 AM
'C' is gorgeous, and gets my vote hands-down! :D

Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Sep 01, 2015, 12:19 PM
(http://i725.photobucket.com/albums/ww258/simorph/IMG_3665_zpswqmyeyqd.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3665_zpswqmyeyqd.jpg.html)


If you ever fancy making a new one, keep me in mind.
thats very smexy  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: YourMaster on Sep 01, 2015, 02:46 PM
 That blaster rifle is 1000 on the sick scale!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Sep 14, 2015, 01:33 PM
Thanks again, everyone!

Well, made a little progress on the Twin Westars  (http://mandalorianmercs.org/forum/index.php?topic=94201.30#lastPost) - they're now ready for dirt washes to finish them off.

(http://i.imgur.com/livt5k5.jpg)

In the rest of the time, it's been non-stop work on the helmets...

Decided to base the custom earcaps on Boba's right earcap, so scaled the WoF template to 111%, which matched the curve of the bottle tops perfectly and set to cutting out all the parts...

(http://i.imgur.com/KLFzGff.jpg)

A simple backplate of 3mm Foamex(Sintra) and then two pieces of 6mm stuck together with CA glue and cut to form all the individual blocks.  I numbered each of the pieces so that I knew which ones fit together and spent several hours slicing and sanding all of the slopes (I put my orbital sander upside down in a vice so I could hold each block at a controlled angle.)  This has to have been the most boring task of anything that I've done so far on the kit...

But, with all 16 sloped pieces shaped, the task came to fitting the ear caps together and then to the helmets.

I like making sure that there's some mechanical connection in everything so things are less likely to come unglued, so I filled the bottle cap part of the ear cap with hot glue and set a bolt into it.

(http://i.imgur.com/wI6UHO2.jpg)

And then drilled a hole in the 3mm backboard...

(http://i.imgur.com/BseD3G3.jpg)

...and then into the helmet...

(http://i.imgur.com/rQtYZf2.jpg)

A combination of CA glue where there was contact, 2-part epoxy glue where there was some contact and then a whole bunch of filler behind that secured the earcaps in place - the helmets curve away a little on the sides, so having a flat baseplate for the earcaps made everything much easier to assemble.

With the attachment method figured out, all that needed to be done was to assemble the earcaps and add some additional details to connect the circular shapes of the bottle tops to the Boba-wedges at the bottoms...

For Jayne (Nikjay)'s helmet - a trio of stiff wires drilled into the Foamex with small tubes around them (again so they're less likely to simply come unstuck) - the greebly on the centre of the left ear is a spare piece from one of my son's old model kits:

(http://i.imgur.com/41Sk3dD.jpg)

For my helmet - the same stiff-wire with a bit of tubing and on both ears themselves a couple of metal parts from an old roller blind...

(http://i.imgur.com/m2UTuG3.jpg)

The backs of the helmets got cut out and the keyhole slots fitted...

(http://i.imgur.com/xyWuqCl.jpg)

This did require a bit of cutting into the skate helmet with the Dremel to accomodate the shape on the inside:

(http://i.imgur.com/HX47i6q.jpg)

And with more filler and sanding...

(http://i.imgur.com/SbXsBlE.jpg)

(http://i.imgur.com/UMXbWPx.jpg)

Then the daunting task of cutting out the centre of the T-visor... Measure twice, cut once!

(http://i.imgur.com/K0Ym7wC.jpg)

More filler and sanding and then finally the task of cutting the visors to fit - these were welding visors from outland sales (http://www.outlandsales.co.uk/product.php?xProd=2248).

The approach we took was to cut out a paper template first, fit it, cut it back where necessary, tape extra pieces of paper where it was possible - the resultant shape wasn't exactly regular due to the mandibles being slightly out on the inside (but obviously corrected with filler and sanding on the outside)

(http://i.imgur.com/pQMfqdQ.jpg)

Cutting the visor proved to be quite easy with a pair of scissors and because the visor comes with a protective sheet on both sides, handling it multiple times wasn't going to scratch it.

To bolt the visor in place, I decided to use small screws, but when shopping for washers at the DIY store I discovered these small plastic screw covers - thick enough to act as washers against the visor, but, with the added bonus that the caps can be closed over the screw heads so you're not going to get a face full of metal every time you wear the helmet!

(http://i.imgur.com/slLNRgt.jpg)

The results...not bad for a first attempt...

(http://i.imgur.com/K77qow6.jpg)

(http://i.imgur.com/Zmxy0cb.jpg)

So to come right up to date, the helmets have now had their first spray of primer:

(http://i.imgur.com/CPie7vN.jpg)

I've added some small kit part greeblies to the back of my keyhole slot to cover a bit of wonky cutting of the top slot:

(http://i.imgur.com/nP5JPvE.jpg)

And here's Jayne's helmet...

(http://i.imgur.com/uZXf43S.jpg)

(http://i.imgur.com/3hNNtXk.jpg)


Plan is to fill a few tiny gaps and get these silvered and then move on to other parts rather than getting too eager to paint the helmets and lock ourselves into a particular design too early.

So, this is how far we've gotten...

(http://i.imgur.com/mZtz1ol.jpg)

And right now, I'm deciphering the WoF Gauntlet templates by building some cardboard mockups...




Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Sep 14, 2015, 02:41 PM
Nice helmets, nice guns. Nice work!
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Sep 14, 2015, 04:59 PM
another superb job ner'vod. you can even tell that they're his an hers buckets... brilliant stuff. :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Sep 14, 2015, 05:19 PM
Thanks guys
Forgot to mention - antennae are made from plastic chopsticks stuffed into half a Letraset Promarker pen, with the transparent bits that cover the rough ends taken from the innards of liquid soap dispensers.
Maaan, I love recycling!
Title: Re: Armour Planning & WIP for 2 of us
Post by: mobcake on Sep 14, 2015, 08:48 PM
Love the work, vod. Great job!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kebii'laar on Sep 15, 2015, 12:27 PM
Absolutely gorgeous scratch builds!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Sep 16, 2015, 02:43 AM
I would wax grandiloquent here about how astounding your work is, as usual...but I've got my two month old in one hand, typing with the other...so I'll refrain.  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Sep 16, 2015, 04:31 AM
 ;D

Thanks all!

Pleased to say that I finally found boots within my budget (just) and picked them up first thing this morning...

(http://s7g3.scene7.com/is/image/ae235?$p$&layer=0&size=281,281&layer=1&size=281,281&src=ae235/98641_P)

Scoria Chelsea Safety boots from Screwfix.com, here in the UK (http://www.screwfix.com/p/site-scoria-chelsea-safety-boots-black-size-9/98641)

Put a pair of spare running shoe insoles into them and they're super-comfy, so keeping me warm in the home office right now and means I've got plenty of time to break them in.

All I need to do is remove the little logo tags...and then maybe figure out how to add toe spikes...and extra armour plates...and boot-mounted flamethrowers... (okay, maybe not the last one)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Korran Orainn on Sep 16, 2015, 04:57 AM
;D

Thanks all!

Pleased to say that I finally found boots within my budget (just) and picked them up first thing this morning...

(http://s7g3.scene7.com/is/image/ae235?$p$&layer=0&size=281,281&layer=1&size=281,281&src=ae235/98641_P)

Scoria Chelsea Safety boots from Screwfix.com, here in the UK (http://www.screwfix.com/p/site-scoria-chelsea-safety-boots-black-size-9/98641)

Put a pair of spare running shoe insoles into them and they're super-comfy, so keeping me warm in the home office right now and means I've got plenty of time to break them in.

All I need to do is remove the little logo tags...and then maybe figure out how to add toe spikes...and extra armour plates...and boot-mounted flamethrowers... (okay, maybe not the last one)

I use the exact same boots! They have a good Boba-esque feel to them, and won't require too much work done :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 06, 2015, 04:52 PM
Short update...

I weathered the Westars...

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

And finished off the Kal Dagger

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

But the thing's that been keeping me busy the most has been scratch-building my left gauntlet...

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

(https://i.imgur.com/G3mbzIi.jpg)

(https://i.imgur.com/Cm1WMZ9.jpg)

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

...to paraphrase, never has there been a more wretched hive of guesswork and bodgery...

I started with the WoF templates but since they don't account for the thickness of the material and they're a little hard to follow, I've kinda had to freestyle it a bit.
But pleased with how it's starting to come together - concealed hinge on the inside of the arm, neodymium magnets to hold them closed and I've built it so that the closure on the left hand side works with the flamethrower (don't ask me how, but it works.)  A couple more bits to add, then it's filler, sanding, electronics and building my right gauntlet and two more gauntlets for Mrs P!

Good job we're shooting for Star Wars Celebration next July!

Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Oct 06, 2015, 05:03 PM
As always, amazing work.
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Oct 07, 2015, 01:49 AM
lovely job on the gauntlet ...you seem to have have the touch for getting some nice curves with the foamex
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 07, 2015, 04:40 AM
Thanks guys

Here's what I've been doing to get the curves....

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

Building cardboard forms to bend around - really quick to do - just cut out the relevant curve guides from the WoF templates (or draw your own if you're doing something custom) and form card over them - making sure you tape the card to the inside of the curve so the thickness of the card you're 'wrapping' with doesn't add to it.

Another trick I've discovered is marking things like cut-outs onto the foam before bending and shaping, then cutting out afterwards - that gives you a harder edge to the cuts - the foam otherwise 'blooms' with the heat and you'll lose the precision of your cuts.

Finally, I've gotten a hold of a couple of really rough files - one with a curved side, the other, circular and a little bit finer grain...

(https://i.imgur.com/9XMlCkZ.jpg)

The files have allowed me to roughly create sandwiches of foam from offcut pieces, glued together with CA glue  that are then really easy to shape with the files.

Much of the 'bodging' I've been doing on this gauntlet has relied on this - building up big blocks of foam and then going to town with the files to make one part of the gauntlet smoothly run into the other part somehow.  (Been really doing this on the fly - the WoF templates are helpful, but nowhere as simple to get your head around as the ones for the helmets.)

Hoping that with a bit of body filler smoothed over the top of these things I'll be able to get some nice, smooth, sculpted curves.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Jorad Werde on Oct 07, 2015, 09:22 AM
wow, those are amazing
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Oct 07, 2015, 10:39 AM
Brilliant work yet again!

These are coming together great!

Oya vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 26, 2015, 02:30 PM
Quickie update from me - I'm spending more time building than I get on the laptop lately.

Anyhow, right gauntlet was much easier after puzzling through the left one...

(http://i.imgur.com/MaLVH6l.jpg)

Lots of playing it fast-and-loose with the WoF templates and improvising around it - such as putting a bit more detail into the launcher on the right hand side, looping a plastic tube (out of the inside of a kitchen spray bottle) and using a PVC pipe and a piece of PVC conduit to create a couple of extra launchers above it - these are two-fold:


With the right gauntlet, my intention was to install some kind of 'screen' so with an LCD digital photo frame keychain (£4 GBP from Amazon) I built the front box out to fit it...

(http://i.imgur.com/ySkGBmx.jpg)

(http://i.imgur.com/vc1gsHy.jpg)

And a cover out of Foamex, a bit of a model kit and some connectors from inside a light switch to sit over it:

(http://i.imgur.com/xydmOih.jpg)

(The cover attaches by slotting in at the top, the front is held in place with a small magnet)

The underside of the top surface of the right gaunt is prepped for wiring - my intention, to run wires LEDs inside the launchers on the right hand side...

(http://i.imgur.com/BMIFJVJ.jpg)

And heaps of filler was applied to all the places that I think the gaunts will be likely to chafe...

(http://i.imgur.com/uzQxWLW.jpg)

The gaunts have been primer, silvered and have 3 coats of gloss lacquer, so they're now in the same state as the helmets - ready for the paint job.

Only slight annoyance with the gaunts is that, like everything else I build, successfully and consistently filling hairline gaps where the Foamex meets is much harder than I'd like.  But I'm hoping the paint job, weathering and chipping will ultimately drown out any of those in the final mix.

(http://i.imgur.com/TnwGy6T.jpg)

I'm choosing to wait until at least the end of the painting stage to wire in any of the switches and LEDs since I figure they'll be a pain to keep having to mask around to stop them getting gummed up with paint.

In other news...I'm starting the prep for the belts...

I discovered TK409.COM's ammo belt tutorial (http://www.tk409.com/images/fett/ammobelt/template.gif) in which he builds ammo pounches out of blocks of balsa wood and then wraps them with faux leather.

(http://i.imgur.com/o8p28WI.jpg)

And here's a template that Man_Doh created too...

Man_Doh's Ammo Pouch Template (https://app.box.com/s/3hish0gkimgpji89u7nm8159exr5dhys)

Rather than go out and buy heaps of balsa wood, I decided to adapt the design and create functional pouches using a cardboard shape rather than a balsa block...

(http://i.imgur.com/1m4wAsa.jpg)

So that's 16 card pouches cut out for both our belts.  Next, glue the remaining 15, cut out and wrap each one in faux leather...  (And I've realised while writing this, that if I cut out a small hole in the front of each I'll be able to give each pouch a magnetic closure...neat!)

...and when I get chance to photograph them, I'm pleased to say that Jayne (Nikjay)'s gauntlets are underway too - I've scaled them at 80% the size of mine and am building them to be more slimline and customised.  I know the measurements are at 80% but boy, do they look tiny in comparison to the Heavy Weapons Platforms I've created for my kit!

Still Much To Do....Stay on Target!







Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Oct 26, 2015, 03:25 PM
love the gauntlets ...nice heavy duty look to them ...used the same style of templates for my belt boxes, through cut mine out of a bit of wood so they are solid ...be nice to see how these come out 
Title: Re: Armour Planning & WIP for 2 of us
Post by: Jorad Werde on Oct 26, 2015, 08:54 PM
I admire the comitment on all of this, i wish I had the patience for it
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Oct 27, 2015, 04:56 PM
Dude those gauntlets!!!  :o :o :o

Amazing!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 28, 2015, 10:01 AM
Thanks  ;D

Here's how my gauntlet making starts - get WoF templates and make one of these for each half based on the curve templates and the length of the inner shells...

(https://i.imgur.com/Bcm7v5c.jpg)

Heat form the inner shells around those, heat form the outer shells around the cooled inner shells, glue with 2-part epoxy or hot glue (something that will fill in the inevitable gaps between the two inner surfaces) and then build on them from there, doing a bit of heat forming to get the sides to match when I put in the hinges.

Here's a shot of Jayne's gaunts in-progress - they're using the right WoF gauntlet scaled down to 80% of mine, and I've flipped them for the left one...

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

(They look so cute and tiny!)

Since Jayne wants them nice and low profile, I've inset another digital keychain into the gauntlet and then made a structure out of Foamex, a model kit part, a bit of the inside of a pen and a light fitting to sit on top.

(https://i.imgur.com/RbhJrK4.jpg)

Magnets on the inner surface latch onto the two screw heads you can see that I've screwed into the top surface of the gaunt.




Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Oct 28, 2015, 12:58 PM
Oooh now that's clever. I may have to steal that idea when I greebly up my gauntlets. How strong are the magnets - how good is the hold?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 28, 2015, 01:32 PM
Those are N35 magnets and they hold pretty well.  I've since discovered what that "N35 "means - it's a grading of strength

So I've since ordered some N52s - I expect them to grip even better...glad I haven't got many fillings...!

(Here's an online calculator to work out what one of these puppies will hold: http://www.rare-earth-magnets.com/pull-force-calculator/ (http://www.rare-earth-magnets.com/pull-force-calculator/))
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Oct 28, 2015, 02:34 PM
Those are N35 magnets and they hold pretty well.  I've since discovered what that "N35 "means - it's a grading of strength

So I've since ordered some N52s - I expect them to grip even better...glad I haven't got many fillings...!

(Here's an online calculator to work out what one of these puppies will hold: http://www.rare-earth-magnets.com/pull-force-calculator/ (http://www.rare-earth-magnets.com/pull-force-calculator/))

Where did you order your N52 from?

I had some N52 magnets that I got from eBay for something like £6 for 8 or 10 of them.
Used them to secure my gauntlets but flexing my arm caused them to pop open.

From a UK supplier I bought N42 magnets (of the same dimensions) at closer to £8 for 5 (I think it worked out £20 delivered for 10 magnets) and holy heck! The difference is phenomenal! For what is apparently 10 levels lower on strength the magnets on one side pulled the other size out of the glue leaving a cocoon of it. I will now buy them from this supplier again as they may be more expensive but they are what they are advertised. Gauntlets no longer open as I move my arm
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Oct 28, 2015, 05:39 PM
That method for holding the screen looks familiar  :P :P :P :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 28, 2015, 06:57 PM
Where did you order your N52 from?


I've just ordered from eBay - I'll see how they do, but I'll take a link to your UK supplier if you have it just in case.

Thanks!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Oct 29, 2015, 03:56 AM
I've just ordered from eBay - I'll see how they do, but I'll take a link to your UK supplier if you have it just in case.

Thanks!

Sure: http://e-magnetsuk.com/magnet_products/neodymium_magnets/rectangular_magnets.aspx?Keyword=EP293

It was the EP293 magnets that I ordered. There are a good size to be able to affix inside the gauntlet whilst also being big enough to give a very good attraction.

I can attest to the strength rating, I struggle getting them apart sometimes so they aren't coming off at a troop :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Oct 29, 2015, 07:25 AM
And really strong glue is needed with N52, I use E6000. its really slow dry but really does the job....... as long as you space the magnets and not put them together.
recently found out that they could even overwhelm E6000 like that :laugh:
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 29, 2015, 06:23 PM
Cool. Great advice, guys. Thanks!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Oct 31, 2015, 04:20 PM
It's Halloween, so we're going as Mando as we can this year.  Here's Mrs P rocking the Boba dress, the twin Westars and a currently non-padded WIP bucket....

(https://pbs.twimg.com/media/CSq8xTRXIAAPeA6.jpg)

Fingers-crossed, tomorrow should see Jayne's gauntlets filled and sanded, silver painted and lacquered by the end of the week.
Have set aside next weekend to start on soft parts and sew those flak vests so we can finally start looking at plates and building some meaty pauldrons to bulk out our shoulders - right now, in just t-shirts, these helmets look huge!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Oct 31, 2015, 08:25 PM
Yeah, I had the same problem. Padding will help, and it always looks bigger than it should be with no armor on. I also painted my earcaps dark color to try to reduce the visual width of my bucket :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kjeldo on Nov 11, 2015, 09:22 AM
Outstanding work!  The helmets are fantastic!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Nov 13, 2015, 08:48 AM
Thanks again, all!

Right, here's our latest update.

Finished off Mrs P's gauntlet sections, sanded them...

(https://i.imgur.com/gdT4tLy.jpg)

...and sprayed with black undercoat

(https://i.imgur.com/ccpmv6L.jpg)

I love how all the disparate parts become one 'thing' once they're all one colour!

Then, had a go at fashioning a missile for my left gauntlet.
This was a shot in the dark, but figured that if I could model a convincing tip the rest would be easy.

Approach I took was to cut a number of Foamex circles and mount them on a plastic chopstick...

(https://i.imgur.com/QzHdYx3.jpg)

Then, using a small cutout of Foamex as a guide, smear around with P38...

(https://i.imgur.com/RuJh2iA.jpg)

Two more rounds of P38 and sanding (put a mouse sander into a vice and then, holding the stick at an angle, rest the tip on the sanding surface and slowly twirl through fingers)

(https://i.imgur.com/c3Jp5sH.jpg)

...the shape looked good enough to fit to some PVC pipes, some plastic end caps off something or other and a few bits of pen insides jammed into the back.  The very tip is the end of a mechanic pencil filled with P38.

(https://i.imgur.com/U7641sp.jpg)

I made fins out of Foamex (and to space them out used a piece of paper wrapped around the tube with regular marks on it) and drilled a hole on the underside where it will sit on the gauntlet...

(https://i.imgur.com/9pNIp8t.jpg)

Once again - ready for painting under a coat of black paint...

(https://i.imgur.com/utI0PWD.jpg)

About to start building knees - using the Wizard of Flight Boba Knees Template, I now have all the pieces cut out and a cardboard jig made ready for forming...

(https://i.imgur.com/atuNx27.jpg)

And soft parts construction has begun. 

This is the version 2 test of the flak jacket as we iterate our pattern...

(https://i.imgur.com/32jCh6b.jpg)

(https://i.imgur.com/fm41wJq.jpg)

We're about to go to version 3, this time, lined with material, with a black pleather outside and with velcro flaps at the sides and neck - taking a leaf from the way that the Bobamaker Jango jacket is fastened on their site.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Nov 13, 2015, 09:04 AM
Looking great! Love the gauntlets, love that missile ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Nov 13, 2015, 09:27 AM
Dude...those gauntlets are work of art.  I have your page saved for reference pics when I start mine!  :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Nov 13, 2015, 09:32 AM
I cannot believe it's taken me so long to see your wip. not as active as I used to be.

Everything here looks amazing. I haven't seen this level of quality and commitment come to the Vok'Chi since Reyn started building. I can't wait to see more. I'd offer to help with anything you need but it looks like you have yourselves covered.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Nov 13, 2015, 10:22 AM
Thanks folks.  Raestin - if you have any questions, PM me - decoding the WoF templates (especially on that left one) was a real pain, so I'm only too happy to share what I've learned in doing this.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Nov 13, 2015, 10:56 AM
Thanks Simorph, I will most likely take you up on your offer!  :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Nov 17, 2015, 01:13 PM
Right, just uploading pics on my progress on the knees since I've been sussing out the WoF templates and there aren't many tutorials out there that explain what to do with all the bits.

I built a jig out of card to form the Foamex around, took the kneecap part and heatformed it over the jig making sure it was central and straight.

With a couple of pointers from the Vok'Chi folks, I realised what the knee parts #2 and #3 were and where they needed to go - heat them and bend them so they go under the kneecaps...

(https://i.imgur.com/pc7LZHA.jpg)

Next step was to bend the side pieces over the jig, making sure that only the part that was supposed to curve got heated and curved - need those sides to be straight!

(https://i.imgur.com/1MK64C1.jpg)

Then it was gluing the sides behind the kneecap, trimming off the excess so that the straight edges of the sides lined up with the edges of the kneecaps....

(https://i.imgur.com/K30VoUb.jpg)

From there, filler and sanding.

(https://i.imgur.com/o1JVyfc.jpg)

As I type, I'm about to do the second pass of filler before I begin any more assembly.


(And I've discovered that while Mrs P has smaller wrists than me, resulting in 80% sized gauntlets, these fit her knees perfectly so after I'm done here, I've got to make another pair to the same measurements!  At least I don't have to make another cardboard jig to form around!) 

Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on Nov 17, 2015, 02:22 PM
.....what is a jig??
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Nov 17, 2015, 02:26 PM
.....what is a jig??

It quite literally means "a device that holds a piece of work and guides the tool operating on it."

When working on cars some exhaust makers have "jigs" that they can build onto knowing that when it is transferred to the car it will be the correct shape.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on Nov 17, 2015, 02:53 PM
It quite literally means "a device that holds a piece of work and guides the tool operating on it."

When working on cars some exhaust makers have "jigs" that they can build onto knowing that when it is transferred to the car it will be the correct shape.

Awesome! Thanks lol.


AND: "... never has there been a more wretched hive of guesswork and bodgery..." <----quote of the year.

I am so excited to see the end result for you guys! Your build is turning out phenominally! Every page is, "Oh!" and "Oooh!" and "Oooh!!". I really hope we run into each other next year. I've already got my tickets for SWCC.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ihala on Nov 17, 2015, 04:51 PM
Absolutely wonderful.  That's the best walkthrough for the WoF knees I have seen, they are rather a puzzle.
Your gauntlets are amazing!  You have shamed me into upgrading, sir!  :D
I look forward to seeing these kits completed.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Nov 18, 2015, 04:49 AM
Thanks again folks.

On the 'jig' question - here it is...

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

Things I've learned:


Hope that helps folks - definitely my jig-making skillz are levelling up with every new piece (helmets, gaunts, now knees) - looking forward to working out a neat but simple way to make forms for the rest of the armour to make life simpler.

Have a great day!
Simes
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Nov 18, 2015, 09:39 AM
Simorph you sir are amazing! Love the walk through for those tricky knees. The WoF templates can be down right puzzling enough to drive you bonkers!

Also, on your gaunts...was that the bottom from a falcon grav. tank I spied?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Nov 18, 2015, 09:41 AM
You sir, are an extremely excellent source of high quality reference material!!   Great job on the knees, definitely up to par with the rest of your kit!   8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 11, 2015, 05:50 PM
Well, time for another update, and since everyone's been finding how I've documented things so far, here's the final steps on the knees...

(And, yep - I know I'd scorched the Foamex before - I was running against the clock and cranked things up a little too high on that particular knee!)

After much filling and sanding (about 3 rounds I think) it was time to attach the blocks to the outsides of the knees.
As much as I glue, I always aim for some mechanical attachment - nothing more embarrassing than something dropping off because the glue gave out.  So in this case I used some old screws and countersunk them on the inside of the knees - dead easy to do with Foamex - I just too my cross-head screwdriver and turned it around on the foam to gouge out a small dent the size of the head, then screwed through into the side blocks.

(http://i.imgur.com/emsO3qi.jpg)

Then I turned them over.  Using the WoF templates' as a guide, I drew the 'D' shapes onto the faces of the blocks, the drew lines from the key points where the 'D' met the slanted side faces of the blocks to where the corresponding points would be on the knee shapes...

(http://i.imgur.com/1nefrjF.jpg)

Then it was out with the Mouse Sander, and then some wet and dry sandpaper (lots of water and a bit of liquid soap/detergent really helps speed things along) to sand down the side blocks and round all the edges off:

(http://i.imgur.com/VWPK1TK.jpg)

And a little more spots of filler and more sanding to finish off:

(http://i.imgur.com/ZAz8KUh.jpg)

Then the issue of the knee darts.

Again, to ensure that things are mechanically attached, I chose to put a couple of ~1.5" screws into the blocks.

(http://i.imgur.com/NAIAkxf.jpg)

And then used the black end of a Letraset Promarker, and some more pieces from the inside of liquid soap dispensers (seriously, I must've reused these parts at least 15 times over our kits - perfect pieces of interesting-looking pipes!) to create the knee darts...

(http://i.imgur.com/WyFxXhH.jpg)

To attach the pipes, I decided to first put hot glue on and around the screws and let it set to bulk them out.  Then I got 2-part Araldite Epoxy gun and mixed up a thick gob of it and painted that around the end of the pipes.  But, before putting the pipes over the screws, I quickly globbed more hot glue onto the screws, pushed the pipes over, and then drizzled hot glue down the ends of the pipes.

No way that those things would come off - epoxy'ed at the base and almost solid with hot glue!

Then it was 3 coats of matte black:

(http://i.imgur.com/t0ODBag.jpg)

And 2 coats of chrome 24 hours later to finish:

(http://i.imgur.com/9DNMQzJ.jpg)

Tomorrow, I'll put 2 good coats of gloss lacquer over them, and then when that's cured, go over that with Rub 'n' Buff silver.

I've found that the gloss lacquer (although it's a great ultra-tough protector) dulls the chrome paint and so it loses a little bit of its metallic look.  So, Rub 'n' Buff sparingly polished over the top brings some of that back.

With knees done, the oddest single thing to build was a Mighty Mando Codpiece.

So, back to the WoF Templates again...

(http://i.imgur.com/vBLlzbO.jpg)

Shaping gently with heat gun....

(http://i.imgur.com/iHvYvzl.jpg)

(I'm used to building cardboard jigs as guides to bend around so this was a little trickier.  One dodge I did come up with to check that the curve was symmetrical was to stand the cod on end, trace the curve with a pencil, cut it out and flip it over - probably me being a bit OCD, but I want a perfectly symmetrically Mando groin!)

Then, I decided to cut out some space for, well, comfort...

(http://i.imgur.com/dYkStI2.jpg)

And then glued the top edge of the flat centre piece to the waist...

Cutting identical wedges for both sides (which guarantees symmetry/front piece not slanting to one side or another), I worked around the centre piece heat forming small chunks of Foamex to fill the space...

(http://i.imgur.com/angKXt1.jpg)

(http://i.imgur.com/Ts6Nqes.jpg)

And from the inside - plenty of room for secret weapons and things...

(http://i.imgur.com/BOOIavz.jpg)

After LOTS of filler and sanding, I decided to add a bit of Swarzy assymetrical greebliness in the form of the back of a junction box from an old security light that looked like it had been destined to sit to the right of the waistband...

http://imgur.com/TuABIo6

Then matte black spray...

(http://i.imgur.com/8KFDiYL.jpg)

And chrome...

(http://i.imgur.com/vCpwGkO.jpg)

Finally - JIGS!

Since we've talked a bit about this in this thread...I made a start on the shoulder armour and wanted to create a nice symmetrical pair.

So - I first drew a rough curve on a piece of paper that I though would match the curve of my shoulder, cut that out and rested it on my shoulder.

Happy with that I took some measurements, went to the computer, fired up Illustrator and created a quick template (using an online calculator to do the math that would ensure that the length of the elliptical curve would be the same length of the WoF template's widest point)

I printed out my paper curve and cut out three card copies, cut out a clean rectangular piece of card (making sure the corners were nice and square) and then with hot glue and small bits of spare card assembled the innards of the jig...

(http://i.imgur.com/F4Di3J8.jpg)

Then it was simply a matter of cutting out a strip of card to the correct width, hotgluing one edge and then slowly bending it and gluing it into place.

(http://i.imgur.com/gH3GIlW.jpg)

To create the jig took maybe 15 minutes including working out the paper template - hot glue and cardboard are just so fast to work with.
There's no excuse when it's this quick and easy and guarantees such reliable clean curves. 

I made a point of drawing the centre line on the jig, an arrow to indicate one side of the jig.

And drew the centre lines onto both Foamex pieces - drawing arrows on the opposite sides of them...

(http://i.imgur.com/xgJoL6k.jpg)

I then got out the heat gun and quickly formed the two pieces...

(http://i.imgur.com/P5hv374.jpg)

The reason for the arrows?  Well, it guarantees that you get two shoulders that have matching curves - if there were any inaccuracies/discrepancies in the jig, I wanted them to be consistently on the back or the front of the pieces of armour - make a left shoulder and a right shoulder so to speak, than two shoulders for the same side.

In other news, work on the first flak jacket is going slowly (I'll post WIP on that once we've gotten it to a showable state - cutting and forming the shoulders means that we can make the shoulders of the flak jacket match the shoulder armour just like Jango's does in the movies)

And with regard to the ammo belts....

All 16 card pouches have now been assembled, and small magnets inset into the front of them (since we might as well make these functional pouches):

(http://i.imgur.com/YPR2WUD.jpg)

And I've just started the steady process of wrapping the card pouches with pleather...

(http://i.imgur.com/R22zsB1.jpg)

1 down...15 to go...


Hope everyone's having a great run-up to the Force Awakens.  Thankfully we're aiming for kits for SWCE in July.
With the way that melee weapons are now 'in vogue' I'm planning to build a couple of vibro swords, inspired by the ones wielded by the Commando Droids in Clone Wars, but with a bit of 1313 thrown in to match the big baddass blaster that for now, is going to be staying safely at home.

Stay safe everyone, have a great weekend.
Simes
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ram'or Kranak on Dec 11, 2015, 07:15 PM
This is looking awesome!  Before I kept scrolling down, I thought that cod was going to be too boxy, but it came out nice.
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Dec 11, 2015, 08:36 PM
an absolute masterclass. :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Dec 11, 2015, 11:16 PM
Spot on work! Love the tutorials. I learn so much from your stuff here! Thanks vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Simmy_82 on Dec 12, 2015, 07:36 AM
This is just awesome. Some serious skills vod. Top drawer skills.
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Dec 12, 2015, 07:53 AM
WOW ...such a nice job as always ... I had tried to make the knees in one part of 5mm foamex and had a side snap on me. Now i have seen how you have done yours i shall have another attempt at it ...so big thank you for showing us how you have been doing things
The joys of rocket/dart launchers from pump style bottles (aussie shampoo serum bottles have a really nice one)
Your belt boxes look interesting ...nice idea from the standard block idea ....shall be watching with interest  :)

Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 12, 2015, 02:58 PM
Unfortunately my aluminium pipe supplies are nil so I have to resort to card and glue.  The cod weighs precisely 301 grammes but I understand it can stop an imaginary blaster bolt from point blank range...
Thanks guys for all the nice comments, glad that my stuff is helping us all figure things out and make better kits!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 21, 2015, 09:44 AM
Hopefully not double-posting here - here's an update of late...

Accidentally dropped one of the knees - it broken off cleanly at the point where the kneepad meets the straight portion of the inside leg - an easy re-glue with Superglue but showed me how fragile these things are - the weight and the shape combined means that when they hit the ground, the part that's only 1 piece of Foamex thick takes all the stress and snaps.

So, I took some PVC guttering pipe, heated it with a heat gun, flattened it and cut some 1" strips that I then heat-formed to go fully around the inside of each knee.  These were then glued with Araldite 2-part epoxy and reinforced with 4 screws - 2 at each end, 2 just inside the knee cap.

(http://i.imgur.com/JE1oP0A.jpg)

Happily I can confirm that they work - dropped another knee from the workbench, it hit the floor and cracked at the same stress point, but held together, requiring only a spot of Superglue to close up the crack...  Glad I figured that out before I try to wear them in action.

Ammo belts making steady progress...

16 cardboard inners, now wrapped with black pleather - found that Evo Stik adhesive was best for this - smear it on, allow it to get tacky and it folds over easily and sticks the pleather.

I adopted a production line approach to get these done, so after making 1 completely, I found the most efficient method was to cut out 15 other rectangles of pleather, then glue all 15 around the bodies of the card, then once that was dry, for each of the 15 make the various folding cuts, then apply glue for 15 tops, then fold 15 tops, etc, etc.

(http://i.imgur.com/O6EqHOW.jpg)

This means you're repeating the same action over and over which means faster progress, and since the Evo Stik requires a small amount of time to get tacky (trying to hold two pieces together before it's had a little time to do this gets messy quick) I found I could start at the end of a row of pouches, apply glue to them all and by the time I got back to the first one it was ready to stick.

Then came cutting, folding and gluing 16 flaps...

(http://i.imgur.com/F2zIGNz.jpg)

These were quite easy to put together (although since the length of pleather has a tendency to curl when glue is applied) I had to glue and fold each in turn.  To get them flat, I laid them inbetween two sheets of baking parchment and stuck a big granite chopping board on top of them overnight.

In other news - decided to have a go at building some melee weapons.

Taking a cue from Clone Wars' Commando droids...

(http://i.imgur.com/DHibH9d.png)

I worked out a template in Illustrator and have so far cut and assembled the following using MDF offcuts...

(http://i.imgur.com/SpcJVqC.jpg)

Both have been glued and daubed in gallons of PVA - want to make sure I seal the MDF really well this time so that I don't suffer the warping problems I did with the blaster carbine (which were annoying and disappointing when they crept in during the last phases of the build - you won't see them, but I will!)

Looking forward to stopping working (so much) over the holidays in a couple of days' time to crack on with the flak vest, start cutting out armour plates, finishing ammo belts and making the vibroswords come to life.

(Saw Force Awakens the other day - thoroughly enjoyed it, hope everyone else does/did too!)

Laters!

 




Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Dec 21, 2015, 09:59 AM
Nah, double posting is only a worry if you're not adding progress. Since you are and it's a few days later, you're fine.

Good plan on the knees, that's always the most fragile part.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 25, 2015, 08:35 AM
And here's the state of our kitchen table before I cleared it for Xmas dinner...

(https://i.imgur.com/7MnHMPh.jpg)


...and as if I didn't have enough Mando to build, here's what Jayne got me for my Xmas pressie...

(https://i.imgur.com/dTMeF26.jpg)

1/12th scale Bandai Boba Kitt!

Happy Holidays, everyone!  ;D



Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Dec 25, 2015, 09:42 AM
I see nothing wrong with the state of that table...? It's even silver for Christmas!  :P

That is a glorious pile of parts, vod.  Slow is a good thing when you take your time to do it right and everything winds up coming out like that ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Sorv Kelborn on Dec 29, 2015, 10:29 AM
you sir have amazing skills, so informative too, thank you very much as I'm finding it so helpful  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 29, 2015, 03:40 PM
You're all so kind.  Glad that my postings are proving helpful.  I want to give back, share the shortcuts, wrinkles and materials I've discovered along the way and give any experienced folks as many opportunities to feed back as possible.

Anyhow...here's today's update - first steps on holsters for Jayne's twin Westars, how I ended up finishing off the rest of the ammo belts,  working out the flak jacket and a first trial of everything together with the WoF Jango paper templates...

First up holsters for the Westars...
I wanted to make something minimal so that all the work that I put into the guns would get shown off (the canon Jango holsters are basically leather tubes that cover the guns from the tip of the barrel right up to the trigger.)

So I got out some cardboard and duct tape, and inspired by the shapes of the ESB Boba Fett sidearm holster, set to work:

(http://i.imgur.com/PIvxsTq.jpg)

I flattened the shape out, cut it out of 3mm Foamex, scored where the fold line would be and heat formed around a pipe, folding the Foamex along the cut line.  The resultant shape looking like this:

(http://i.imgur.com/hnVY1AZ.jpg)

These need filling, holes drilling in the tops to allow them to be attached by pleather straps to the ammo belts.  I intend to paint these up as chipped painted metal so they'll add some extra colour/texture to Jayne's outfit (which will feature a lot of black in the soft parts.)

Then, onto the ammo belts.

Xmas presents brought me some new belts, so I repurposed the old ones for us.  Since they needed to sit on our hips, not our waists, I found that I had to glue and rivet a small length of spare belt  to get the lengths we needed:

(http://i.imgur.com/C3INMs7.jpg)

I then cut out some pleather twice the width of the actual ammo belt and laid the leather belt onto it, gluing it down with Evostik Impact Adhesive.  Since the leather belt is about half the size the ammo belt needs to be, I took strips of cereal packet card and glued layers of it, first overlapping the belt (so there'd be a smooth transition from the real leather belt and the card) and then below the belt to bring the interior to the right thickness/depth that I needed it.  (BTW the leather belt sits at the top of the ammo belt so it bears all the weight.)

Here you can see the back of the pleather, with a strip of cereal card, then the belt on top of that, with a thinner strip of cereal card below it... (Apologies for having insufficient WIP photos here - everything got very sticky for the next 20 minutes...)

(http://i.imgur.com/OckaaKi.jpg)

With the sandwich of real leather belt and card complete, I folded the pleather over and glued it to the belts.  Because I'd underestimated the width of pleather I needed to wrap the belts, I cut a small strip to cover the gap, folding its edges over before I glued it.  In the end, I thought the detail it added looked so interesting I decided that what was going to be the inside of the belts was going to be the outside.

Here's one of the belts being clamped so the industrial Velcro closure has as much chance of sticking as possible...

(http://i.imgur.com/rweqEOO.jpg)

That done, it was time to attach all 16 of the pouches - Jayne had done the sewing detail for me on the flaps, so I set up a small production line, gluing first the bottom of the flaps to the pouches, then putting the pouches on the belt, then gluing the top of the flap to the top of each pouch.

I found this to be the most efficient way to work, and better to do on the belt rather than off it since in my first attempt I'd underestimated the amount of slack I needed to leave at the back of the pouch to make the belt loop...

(http://i.imgur.com/MP747Tx.jpg)

Then, the final step - small magnets to make the closures on the flaps - found the easiest way here was to drop a magnet onto the pouch so it would find its position, put a spot of superglue on the magnet and then press the flap down...

(http://i.imgur.com/i49Cl9e.jpg)


So there we have it, two ammo belts with practical pouches - a really satisfying little project.  Total cost: price of the hot glue, Evostik glue, the pleather, some magnets and a bit of Velcro - everything else - cardboard, cereal card, two old leather belts - zip, nada, nothing.  Quite pleased with that one.

(http://i.imgur.com/mWBXpWy.jpg)

(And the extra pair of straps on the lower belt with some Chicago screws in - they'll attach to the Westar holsters when they're finished.)

Going back some time this is how we got to the flak vest.

We first leapt in and using some spare fabric attempted to create a prototype flak vest using one of the templates out on the net - that just didn't work for us - if I recall some of the instructions were mangled in the tutorial and were never corrected, so ultimately hacked around with the basic shape we'd made, comparing it to the Boba Maker Jango Jacket photos (http://www.bobamaker.co.uk/Jango_Jacket.html) and making as many iterations as possible until we got something that fit...

(http://i.imgur.com/32jCh6b.jpg)

(http://i.imgur.com/fm41wJq.jpg)

With that done, we took the prototype apart, laid it flat on some brown paper and made a new pattern - the intention being to put Velcro closures on both sides and on the shoulders so we could do the same kind of closure as that on the Boba Maker site.

Here's the front - note the 'Velcro' flaps...

(http://i.imgur.com/JlJyM3W.jpg)

And the back...

(http://i.imgur.com/DNmfVoi.jpg)

Lots of sticky tape as you can see - the result of several iterations cutting, trying it, taping new pieces on - that's the way we worked it out.

To solve the problem of finishing the edges of the pleather, we realised that if we effectively lined the flak jacket we could get a reasonably slick-looking result.

So, we cut out our shapes in plain black cotton-like fabric, allowing a whole inch around them:

(http://i.imgur.com/b989eKG.jpg)

...and also in pleather...

(http://i.imgur.com/dfdo0e6.jpg)

Laid the pleather facing side down onto the black fabric, and Jayne sewed around them:

(Note the extra stitching line where the Velcro flaps are on the front...)

(http://i.imgur.com/yh63LxE.jpg)

(http://i.imgur.com/PxgV398.jpg)

We then trimmed the excess as much as we dare and cut many small V shapes in on the inside of all the curves...

(http://i.imgur.com/3elDXt1.jpg)

That done, we turned both front and backs inside out.

The result:

A front...

(http://i.imgur.com/WbDpQmz.jpg)

...and a back...

(http://i.imgur.com/vv9QLtC.jpg)

...with hidden stitching all around.

All I had to do then was attach Velcro in the appropriate places...

And here's a top tip from me...

DON'T USE GLUE BACKED VELCRO AND THEN TRY TO STITCH THROUGH IT -

I NEEDED A PAIR OF NEEDLE-NOSED PLIERS TO PULL EVERY PAINFUL STITCH THROUGH!
   :'(

Public Information Announcement over, to make the shoulder pieces, I made the 'shoulder bell' armour first, then made a pattern to fit those since I wanted them to fit like the Jango ones.  Although I use the Boba templates since they're a little bigger and I wanted to make sure my shoulders bulk out as much as possible to help balance the size of the helmet (which is approx. 111% of the size of the standard WoF templates)

So, tonight has been the first proper test - put everything together, attach paper templates using lots of masking tape...

(http://i.imgur.com/Z13j7F0.jpg)

...and try things out...

(http://i.imgur.com/8dkTKW2.jpg)

Ignoring the fact that some of the paper started to come off as we were taking shots and the obvious stuff here - need to trim leg parts down somewhat, I'm pretty pleased with this first ever try on.  Was really hoping for the wide shouldered bull-headed look and that seems to be coming through.

Holidays not over yet - looking forward to cutting out many parts and ordering paracord for that girth belt tomorrow!




Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Dec 29, 2015, 03:45 PM
(http://i229.photobucket.com/albums/ee43/reapwind/Profiling%20N%20Stuff/picgifs-mind-blown-3830258_zps1c390880.gif) (http://s229.photobucket.com/user/reapwind/media/Profiling%20N%20Stuff/picgifs-mind-blown-3830258_zps1c390880.gif.html)

Every update I see has me in shock and awe.

You make me want to try upping my game eveyrtime I see your work.

That all together shot is amazing, I can't wait to troop with you both!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Dec 29, 2015, 03:50 PM
Yup, you're channeling Jango there for sure.

Y'know, it's not often that I'm impressed at the "wearing the templates" phase, but damn, you just wear them so well! (It helps, of course, that you decided to do all of the hard parts first :P)

And yeah, those thigh plates gotta get trimmed - they always do, they're too big in the template file. The WOF templates are a bit quirky in some spots, but they're still better than starting from scratch.
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Dec 29, 2015, 04:48 PM
looking awesome mate.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Dec 29, 2015, 05:48 PM
the Boba cod and Jango thighs imo really don't do well together, have you thought of filling the space with leather work of some sort, holster, large pouch?
possibly Boba leg pouches?

its only an idea

Darn you make this look so easy  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Zharatustra on Dec 29, 2015, 06:22 PM
looking great! i want to thank you for documenting so much. its a very good reference and most helpful to my own progress.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 30, 2015, 05:12 AM
Thanks guys, as always.

Colin - agree with you about the cod area - those thighs definitely need some taking down (I understand from Kris that the WoF templates are generally considered too big at their default size) and will start by looking at the Jango pattern's cod to understand what to do with that area (which, tbh will mean attachment will be a lot simpler and likely more comfortable!).  I'd started with Boba but hadn't recognised the subtleties in the difference in patterns when I began building.

But as a first shot, I'm pleased with the results.  Busy day today so building plans may be scuppered.  Hope you're all having a great time and thanks again for all the feedback and comments!

Title: Re: Armour Planning & WIP for 2 of us
Post by: Vhiran Kord on Dec 30, 2015, 08:01 AM
Wow! Just, seriously, wow! Amazing creativity and attention to detail. I find myself swinging between believing that I too could build an awesome costume and props from everyday materials at minimal cost by following your outstanding WIPs and tutorials, and going and sitting in the corner and taking up knitting because you sir have set the bar so stinking high it's not fair on the rest of us (especially those for whom these sort of challenges are quite alien). What I wouldn't give for a copy of your Illustrator files. ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Dec 30, 2015, 09:02 AM
Top notch work Simorph, but I'd expect nothing less from you!!  Great job on the vest/belt/pouches!!!!

I also have the Boba cod w/ Jango thighs.  I had to do some pretty serious trimming!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 30, 2015, 09:28 AM
Shucks guys! Thanks

Any questions - PM or drop me a comment here - I'll do my best to answer them, but I'm making this up as I go along too!

BTW: Colin (Ashen) made a great point to me regarding getting a better shot for plate sizing/spacing, so here it is (original photo taken more at waist height as per app photos so as to show the size of the bucket in balance with rest of kit)

(https://i.imgur.com/lzWMDtI.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Dec 30, 2015, 04:30 PM
fantastic work as normal and well done on the soft parts and nice handy hints as normal ...all ways look forward to seeing whats new on there ...keep up the great work ...not long now
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kjeldo on Dec 31, 2015, 02:42 AM
Outstanding work!  Keep it goin'!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 31, 2015, 12:12 PM
Thanks dudes!

Right - after feedback from everyone here and in the Vok'Chi chat thread, I'm trialing the 5'7" WoF templates, which seem to be working better...

(https://i.imgur.com/Nk5FLRj.jpg)

Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Dec 31, 2015, 12:24 PM
Yep those are better. The other ones were just a hair too big, I think.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 31, 2015, 06:09 PM
Well, thanks to the fabulous Mr Ashen Kelborn over e-mail we made several iterations of the plates and he advised me on how best to trim the bigger plates (from the 5'9" template) to fit.

His really smart advice was to cut from the inside out...

So -
1. remove space around the chest diamond, slide that in
2. trim the top of the ab plate to create the space between the chest and the abs
3. trim the sides of the ab plate so that the outside of the chest forms a straight line with the ab plate
4. tweak the shoulders so that they don't overlap the outside of the top of the chest

(http://i.imgur.com/pKvhaW3.jpg)

With that done, one final fitting...

(http://i.imgur.com/21OE29v.jpg)

Still retaining the height and sense of size of the original plates but as narrow as the 5'7" template plates!  And the 'fangs' that extend from the chest plate retain their thickness to.

Many thanks to Ashen (Colin) and everyone for their feedback and advice here.

May I wish you a Happy New Year and fingers-crossed that all goes well for 2016 and that I might be able to meet up with some of you in a finished kit some time!







Title: Re: Armour Planning & WIP for 2 of us
Post by: Danifae Kelborn on Jan 01, 2016, 06:44 AM
That looks spot on, keep up the good work
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 05, 2016, 05:40 PM
Thanks!

Well - after all the help in getting the paper templates sized correctly I've been cutting the many, many parts of the armour out of 6mm Foamex and additional plates out of 3mm Foamex to give some extra relief (and give me lots more edges to catch weathering and scratches) shaped to reflect key muscle groups (like pecs, abs, calves).

These have all been shaped with the heat gun, dremelled around both the inner and outer edges at a 45 degree angle, and then every edge sanded with some 600 grit wet-and-dry to turn those angular dremelled edges into curved ones...

(https://i.imgur.com/VcG9gaA.jpg)

I daren't think how many feet the entire periphery of all these parts adds up to, but suffice to say it took a good few hours since the last update!

And finally...THAT THING...

(https://i.imgur.com/B75Po32.jpg)

The backpiece, indeed proved to be as 'special' to form as everyone talks about.

The trick I found was to work systematically around the piece, fold in the sides first, then curve the top down and then adjust and adjust again.  I found that it was easiest to do a small adjustment to one side, then immediately do the same adjustment to the other side - my fear was that I'd get one side 'perfect' and then struggle to replicate the steps to make the other side work in the same way.

One problem I did have was getting the material above the arms to curve over as much as I'd wanted - there was way to much Foamex in the sides above the arms to allow the top of the back to be pushed over and forwards without the sides buckling out.  To solve that, I cut a couple of 'V' shapes up into the curve - this removed enough material to allow the back to be pushed forwards and over.

Final thing was closing up a small gap above my shoulders - to fix that, I cut custom shapes to slot in and fill the gap, then piled on the P38 and dremelled and sanded to finish.

Next job - gluing the additional plates on!


Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on Jan 08, 2016, 03:40 PM
Hey vod. As usual everything looks spectacular! I was just wondering. The P38, do you know if it is more like Bondo or Apoxie sculpt?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 08, 2016, 06:00 PM
As I understand it, P38 is the UK equivalent of Bondo. For Apoxy Sculpt I'm guessing the UK equivalent will be something like Milliput.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Jan 09, 2016, 03:19 AM
As I understand it, P38 is the UK equivalent of Bondo. For Apoxy Sculpt I'm guessing the UK equivalent will be something like Milliput.

^^^^THIS^^^^^
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 09, 2016, 05:37 AM
Thanks Ashen.

Yep - the P38, mix up as a paste (golfball sized blob of filler + pea sized blob of hardener) and smear on.  You have about 5 minutes working time (although you can speed that up if you add a little more hardener) and it sets rock hard but sands down super-smooth with wet-and-dry.  One trick I have found is that you can cut P38 with a craft knife as it begins to cure - so if you're struggling to build up a large amount and can see you'll have a lot of sanding to do when it sets, wait a few minutes after applying until it's on its way to solidifying and use a shape knife to cut off the excess before leaving the rest to set.

I sometimes find P38 a bit tricky to apply for small spot/seam fixes since you're working against the clock with it and so coordinating yourself to get small spot amounts into seams can be a little challenging.  So in those cases (like filling in the seams where my trauma plates meet the main armour plates) I've used Vallejo Plastic Putty (http://www.amazon.co.uk/gp/product/B000TSBJEO (http://www.amazon.co.uk/gp/product/B000TSBJEO)) - that's easy to squeeze into gaps with its long nozzle and can be wiped to a smooth line with a finger/flat end of a screwdriver.  This takes longer to cure, but is less trouble for small seams than P38.

Milliput, like Apoxie is much thicker - a two-part putty - I've found is better for modelling  shapes than filling gaps (although it is possible, and I have done a couple of infills by jamming in Milliput and then a wet finger to get a smooth finish.)  Where I've hit problems is getting Milliput to adhere to something - lots of pressing blobs onto a surface/into a gap to finally get it to 'bite' and also kneading the two lumps of putty to get a mix can be a slow process.

So, yes - remodelling shapes, filling in majority of pits, gaps, holes and seams I've used P38.  Vallejo Plastic Putty for very small seams and tiny spot repairs.  Milliput for bits of major additional resculpting (although, for me, it's not my most favoured method.)

That's my experience with these products, hope that helps.

One other cheat - for getting a rock-solid in-fill on some gaps - Bicarbonate of Soda and Super Glue.

Fill the gap with a teaspoon of bicarb and wipe off any excess, then carefully drip Super Glue onto it.  It will immediately 'kick' the glue into curing and you'll get a rock solid fill in.  If there's any excess sticking out of your gap, you'll have to sand it back, and if you want a seamless finish, go over with P38 or Plastic Putty afterwards.

But - if you need to fill a small gap between two pieces AND guarantee a super-glue-strength bond at the same time - a little simple workshop chemistry is invaluable.  (Here's a demo of the technique: https://youtu.be/slCMkvEfK_U?t=158 (https://youtu.be/slCMkvEfK_U?t=158))



Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Jan 09, 2016, 08:46 AM
Will have to try the baking soda and super glue on my gauntlets ...couple of odd spots that are proving awkward to get filler to take ...have a rattling piece of putty inside one ATM where it didn't bond in the gap

 
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 09, 2016, 09:18 AM
Hope it works for you.  It sets like rock for me.  If you have trouble getting the bicarb to fill the gap, just wedge some paper, card, aluminium foil or a bit of Foamex in to give you something to act as a surface to stop the bicarb dropping all the way through, then drip the Super Glue onto it - the crystals that result from the bicarb/glue are so strong that the bit of weak backing won't hurt.

If you're really having trouble filling a big gap - one trick I use when filling holes in cavity walls (drywall to you across the pond!) is to get a piece of card bigger than the hole, put a piece of string through the middle of it, bend the card enough to push it through the hole (hold onto the end of the string!) and then with the card inside the hold pull on the string and hold it - this gives you a surface to then put the filler onto, and when you're done, just snip off the bit of string.  Although I haven't tried it on my kit, the same trick will work with some card, a bit of thread and P38/Bondo, I'm sure.

BTW - Super Glue + Bicarb is an exothermic reaction, so you will get some heat being formed with the reaction (although your fingers should be well away from glue anyway).  As I understand it, the 'fumes' that you may see when combining the two are water vapour and CO2 being released as the glue polymerises (I'm no chemist, but that's as much as I can gather from reading up on this myself.)  Suffice to say, as with all these chemicals, use gloves, well ventilated area, don't inhale fumes/wear a respirator, etc.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on Jan 09, 2016, 07:23 PM
Awesome, thanks I was trying to follow your example for filler in the knees and no one at the hardware stores had any idea what I was talking about lol :laugh:
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 10, 2016, 11:04 AM
 You're welcome! Any other questions you may have just ask (my first time doing this but I'm only too happy to share any tips/info I have)
Aside from briefly meeting up with Reyn & Vardabob at Notts Comicon last year we haven't had chance to  up with any of the Vok'Chi in person yet, but thanks to the power of the Intertubes folks like Ashen, Kris, Nala and Saz have been ultra helpful with their advice.  But hoping to get the kits built to that OM standard and getting the chance to use our powers for good later in the year (I really enjoy using my art skills to raise for charity and this has been really cool so far as usually I'm making art and giving it away to be auctioned, but this time I get to keep the art and perhaps meet in person some of the folks we're likely to be helping)
All great stuff....and I've always wanted a Boba Fett outfit since I sent away proofs of purchase for that special Star Wars figure back in '79!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 10, 2016, 12:40 PM
And an actual update as I've had enough time today to test everything out before I go to priming.

Here's everything attached with masking tape - obviously the spacing on the chest is off and elements are a bit misaligned - the consequences of the tape slowly becoming unstuck during the process of waddling over to the corner for photos, but size-wise everything seems to check out:

(https://i.imgur.com/8RmSqa9.jpg)

In the end as you see, I decided not to trim the thigh plates, instead pushing them around to the side.  One mod I'm going to make to the right thigh is to add a rigid holster (for an as-yet-unbuilt-sidearm) and perhaps some additional trauma plating on both thighs in the same style as that on the sides of the calves.

Intention is to get everything primed, silvered, sealed with gloss acrylic and then Rub 'n' Buffed so then I can start work on Jayne's plates (which require us to make a flak jacket for her before we can kick off in earnest on those.)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Jan 10, 2016, 04:42 PM
I strongly suggest that before you start to paint your back plate. You should check into the fitting of the shoulder tabs as they seem to be lifting quite a bit (they look to be pretty horizontal but your shoulders slope downwards from your neck, which is what i think is causing the gap) It's not an uncommon thing to get knocked back by the app team for so best to tackle it now rather than later.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 11, 2016, 07:02 AM
Thanks for that - I've figured out how I took a mis-step on the backplate forming. I've formed the sides so that they're parallel to my body all the way up to my shoulders, instead of flaring out gradually to rest on my shoulders - likely the reason I was having so much trouble forming them in the first place.

D'Uh!

Will go back and attempt to re-form them....or grab a new sheet of Foamex and start from scratch with my new knowledge of this whacky 3D shape!

Many thanks
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jan 11, 2016, 07:58 AM
You could try cutting the slightly raised section right behind the neck that the Boba templates use. I find that they allow for a far better bend of the shoulder tabs since you can keep the back straighter.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Jan 11, 2016, 08:06 AM
Thanks for that - I've figured out how I took a mis-step on the backplate forming. I've formed the sides so that they're parallel to my body all the way up to my shoulders, instead of flaring out gradually to rest on my shoulders - likely the reason I was having so much trouble forming them in the first place.

D'Uh!

Will go back and attempt to re-form them....or grab a new sheet of Foamex and start from scratch with my new knowledge of this whacky 3D shape!

Many thanks

You can adjust that m8, you don't need to start anew
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Jan 11, 2016, 09:53 AM
Just noticed the thigh plates are backwards. The cut out should be on the outside of your thigh. They are supposed to allow you to draw your pistol/hip weapons easier...or so I have read in another thread.

Other than that, to quote Billy Crystal "You look Marvelous!"
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 11, 2016, 10:06 AM
Thanks for the help, folks.  Fingers-crossed I'm hooking up with Reyn this weekend to attack the back plate together.

On the subject of the thighs - yep - I'm remodelling them at the moment - actually prefer the larger surface area on the outside of the thigh since it is allowing me to build rigid holsters/attachment points for sidearms and they give me more "cod clearance".
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Jan 11, 2016, 10:23 AM

On the subject of the thighs - yep - I'm remodelling them at the moment - actually prefer the larger surface area on the outside of the thigh since it is allowing me to build rigid holsters/attachment points for sidearms and they give me more "cod clearance".

Makes total sense. Hard mounted holsters sound great! I'm 50/50 on doing the same for my side arm, but still toying with a leather drop holster too...so many choices lol

Wanted to offer help. I know the WoF templates can get swapped up pretty easily.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 11, 2016, 10:31 AM
No, please chip in! Saves me trouble and helps anyone else that views this thread.
Thanks!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Jan 11, 2016, 10:49 AM
The deathwatch thigh's have hard mounter holsters and I love them for it. I am currently building my second set. I believe the look of your's being incorrect to some is due to you putting your thigh plates much further around the leg than Jango (as he seemed to wear them slightly more frontal).

These are designed to sit right on the outside of the leg and I can say the curved front and straight cut back are amazing for comfort

(http://i686.photobucket.com/albums/vv225/Elihdorr/Cosplay/Mando%20-%20Death%20Watch%20Kenobi/Armor/IMG_0418_zpssi1ejjra.jpg) (http://s686.photobucket.com/user/Elihdorr/media/Cosplay/Mando%20-%20Death%20Watch%20Kenobi/Armor/IMG_0418_zpssi1ejjra.jpg.html)

On my current kit I also have them but dont have any clear photos of me wearing them

Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 11, 2016, 12:57 PM
Yep - saw those the other day, started building my own versions and decided to position my plates around the sides to create that effect.
And yes, did my research earlier - yes the WoF templates are indeed the right way around (checked the original templates, photos of Jango and other approved kits on here!)
Have a little more filling/sanding to do on right thigh for (an as yet unbuilt sidearm) but contemplating some kind of attachment for the Kal Dagger or some 'grenades' on the left thigh.

Thanks!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 18, 2016, 08:05 AM
Update from the weekend - all to do with attachment, tailoring and fixing...

First up - decided to build a physical clip out of Foamex to go over the two Velcro-ed ends of the ammo belt - to take the strain off the Velcro and reduce the chance of it coming loose/off and also to add a bit of visual interest to the back.  Taking a leaf from the various Stormtrooper/Scout Trooper references which use a horizontal, cylindrical prop to cover a variety of sins at the back of the costume, I fashioned this...

(https://i.imgur.com/KF26VWs.jpg)

(Made from a small soccer ball pump, bottle tops, piece of a contact lens tray and various other small greebly-like fixings from the bottom of the toolbox)

Plan is to paint, make it look like metal, weather, etc.

This weekend though, I had the pleasure of being joined by Paul (Reyn Vok'Chi) who offered his assistance in getting my backplate shaped correctly and brought over his kit to show us how he's been attaching all the various parts.

We spent most of an afternoon with a heatgun and box cutter - with Paul's solution for the backplate being to cut large 'V' shapes from above the arms into the body of the plate to allow the curves above the shoulders to get in tighter.

Suffice to say, after some reinforcements and filler the backplate looks far better (and fits much neater)

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

On the inside of the plate I decided to heat form in a couple of strips of Foamex and then secure them with a combination of 2-part epoxy small screws before slathering everything in P38 filler (and making a number of countersunk holes on either side of the V as Paul had shown me to allow the filler more chance to grip into the backplate, rather than simply sitting on top of the repair)...

(https://i.imgur.com/aAz6YtJ.jpg)

We also spent a good amount of time doing some plate tailoring and ended the afternoon with my vest marked up for the plates to be attached.

First order (no pun intended) was to trim the collar plate to bring it in slightly and to match it to the backplate...

(https://i.imgur.com/TmK63D0.jpg)

This required taking a small segment out of the centre of the plate, shuffling everything in and reinforcing with a Foamex plate, screwed and epoxied.

On the flipside, a trauma plate covers the 'sins', and I decided to give the thing a bit more of a Star Wars asymmetrical aesthetic by putting in a cosmetic trauma plate on one side.  This makes the smaller middle plate look less 'lost' and gives me once again, more edges to weather against.

(https://i.imgur.com/7H4zCSU.jpg)

On the subject of chest and ab plates, Paul gave me a few hints on shaping to make them fit better.  Now, since I'd already painted the plates silver and put a clear lacquer on them, I didn't want to hit them with a heat gun and set fire to the paint.

Instead, I flipped the plates over, wrapped them in kitchen foil and hit them with the heat gun from the back.  The result - the paint blistered but didn't ignite (do this in a well ventilated area-ya-de-yadda) and meant that I could reform the plates with only minor heat damage to the front surface.

That said, though, as a result, I discovered a neat way of getting the appearance of physical damage on the plates in a semi-controlled fashion using the heat gun...

Wrap the front side of the plate with crinkled foil and hit with heat for a few seconds...

(https://i.imgur.com/LyHuY01.jpg)

Then take off the heat and quickly pull the foil away from the plate - the result - surface pitting and indents in a randomised fashion, and as you can see, because the foil wasn't tucked in right up to the trauma plate, there's a nice area of clean separation between the 'heat impact' and the edge of the trauma plate above.

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

I decided to throw in a couple more of these flourishes to the plates, being mindful to not overdo it and to make sure that the damage to the upper left of the ab plate was continued on the bottom right of the left chest plate...

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

I intend to add a few more similar pieces of damage around the rest of the kit bearing in mind the 'story' behind the damage (here, for example - it's a massive hit to the right upper ab and a glancing shot ricocheting off the left chest (which means I'll also add a small bit of damage to the left shoulder edge....and weather the flight suit with burn marks as appropriate)

As goes the rest of the kit - now I have a guide for where my plates should fit (thank you Reyn/Paul!) and seeing the sucess with which Reyn's kit holds together with physical connections (in his case, lots of M5 bolts) I'm venturing into the world of snaps...

Following this tutorial (http://mandalorianmercs.org/forum/index.php?topic=7796.0)

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

24 hours after setting the epoxy putty the snaps seem to be holding so hopefully I'll be able to attach some key armour pieces to the flak vest properly - start small with shoulders and chest diamond, see where that goes.

Finally - the Cod!

Reyn's kit features a neat design in which the two halves of the cod are hinged with a metal hinge on the left and are bolted together at a closure on the right, with the whole piece being shaped to simply rest on the hips with no need to have any additional strapping or fixtures to keep it...erm...'tamed'.

Because we don't have the requisite hinges and bolts, we've decided to take a slightly different tack, using an old webbing belt to sling over the hips, snaps to attach the two pieces and are currently debating whether to put the closure at the side or, behind the centre of the cod, which will require a bit of unsnapping to remove - trial and error here will provide us with the best solution.

(https://i.imgur.com/hDibC8t.jpg)

So a terrific amount of progress this weekend - everything starting to come together and create a single costume, and huge thanks to Paul (Reyn) for taking the time to come over, share his skills, expertise and knowledge - really helped us understand how all these parts work together.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Jorad Werde on Jan 18, 2016, 09:16 AM
that tin foil effect looks great!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Jan 18, 2016, 09:49 AM
Simorph, that's some fantastic work, as always!  Love the tinfoil affect.  And, as you can see below, I'm definitely a fan of trauma plating!!  :D :D :D

(http://i.imgur.com/NcE7CPFl.jpg)
(http://i.imgur.com/vrx4gk6l.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Jan 18, 2016, 09:55 AM
Think me saying great work is getting redundant  :P

You're work was awesome anyway, combining it with Reyn is just crazy hehe
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Jan 18, 2016, 05:05 PM
My, you have been busy! I love it when an accident turns out looking cool too. Nice work as ever  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 18, 2016, 06:00 PM
Well, as you'll attest, we Derbyshire Mandos don't muck about!  Thanks so much for your time, help and advice, dude - looking forward to hooking up again with a completed kit!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jan 18, 2016, 09:17 PM
Wow.  Just wow.  I've been away from the boards for a bit, and when I saw your update.....I'm still trying to process all you've done here.  Amazing work, my friend.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 19, 2016, 04:30 AM
Thanks buddy, much appreciated.  Hope all is turning itself around for you and yours.  Sending you the best from here across the Pond.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 24, 2016, 01:28 PM
Small update from me while taking a break (working all hours, and all weekend as we have a HUGE week coming for the game I'm working on) so sadly, not much work on the kit.

That said, earlier in the week I had the chance to test out the snaps that I'd added to the armour plates.  The method used in this tutorial (http://mandalorianmercs.org/forum/index.php?topic=7796.0) half worked...

That is to say, that I tried snapping a snap on-and-off the connectors that I'd attached to my shoulder plates and cod plates and found that although the shoulder ones held, the ones attached to the cod easily came away.

So, I decided to come up with a different strategy for attaching snaps:

(https://i.imgur.com/dUg0itn.jpg)

1. A piece of 3mm Foamex, punched through, with both halves of the mail snap assembled through it.
2. Heat the Foamex and press it against the plate so that it forms against the plate (the metal snap, being hot will create a small indentation too)
3. Allow to cool, roughen the underside of the connector Foamex plate and the place on the plate where the connector is to be stuck
4. 2-part epoxy (Araldite) the connector plate to the armour and clamp for a while to set (pieces of card between clamps so you don't leave marks)

After 24 hours of curing, there's a pretty darned solid bond, so I was able to attach the snaps to the cod in a really robust manner.

To complete the cod attachment, I decided to use an old webbing belt with snaps, and create a number of small belt hooks using flattened out PVC pipe bent into shape and epoxied so that the cod's weight is distributed on the belt and attaching/removing the cod requires the least number of snaps to be unfastened (my fear would be unsnapping mid-event and finding a snap connector coming off)

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

The result:

(https://i.imgur.com/9UsquHL.jpg)

When I get five minutes, I'm going to add a couple of trauma plates to the kidney plate both for style reasons and for strengthening.

Right, time to get back to work and when next week's over, get back to working on the kit!



Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Jan 25, 2016, 03:07 AM
Nice idea with the snaps. If my glue doesnt hold up I think I'll be stealing this  :P

Is that a front and back codpiece there? Looking great as always. I think with all this armour you need to get building a mini gun or rocket launcher to complete the look.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 25, 2016, 03:37 AM
Yep, that's the Boba templates.

Reyn showed me his system of doing it where he has the kidney plate attached to the cod with a hinge and then a bolt on his right hip to close - the whole thing is shaped so that the waist simply rests on his hips.

It's a really neat idea but I worried about being able to carry off the connections and was concerned that a lot of stress could be put on the large lengths of Foamex - would be my luck to snap it on a first troop and be literally left with my armoured pants around my ankles.

That gave me an idea about hanging everything off a belt that rests on my hips, and gave me the chance to experiment with snaps - I'd bought a stack of them and wanted to find a way of attaching armour mechnically that didn't require me to drill a bolt through the plate and have to fill/sand the front side. 

This combo of snaps, Foamex, heat forming and epoxy seems to work.  Just looking forward to getting a bit of spare time to finish off all the rest of the plates, work out the best way to add strapping to leg pieces and pull everything together.

Must admit, have considered jetpack as a post-app addition, although I'm still in the middle of building twin vibroswords in light of the LFL weapons stuff and wondering how I might implement a ninja-style crossed vibroswords mounting for the back...


Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Jan 25, 2016, 04:56 AM
Yay vibroswords! Could you cross them over the back of the jet pack? Guess other option would be to implement a holster for each sword on either side of jet pack. Have them straight up instead of crossed?

I will admit the weapons ban persuaded me to make my teeth knives as the bes'kad wasn't really cutting it.  :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 01, 2016, 01:20 PM
Super busy work-wise, so I've been slowly making progress in spare moments - which is a good thing, since a great deal has been quite repetitive but necessary.

First the exciting bit - building a solid holster for the right thigh and an array of grenade weapons on the left thigh.

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

Since my priority is getting the armour done, I decided to be a little reckless and build the holster to look and feel right with the aim of building a sidearm to fit it later.

On the left thigh, I decided to mount a trio of PVC pipes using Chicago screws so that I can paint the armour and the 'grenades' separately and reassemble them when they're done.

Thinking about a mounting system, I was first tempted to build it out of a few blocks of Foamex, then thought that the true 'Swarzy' solution would be to have some kind of metal racking bolted to the piece.

My solution - butcher a plastic trouser hanger (a trick I also used on my carbine's scope rail) since there are lots of rigid and unusual shapes on those things.  To cover the embossed lettering on the insides of the hangar pieces as well as to give me a sturdy mounting for them, I drilled a couple of holes at either end and ran thick wire along the groove to cover the lettering and then poked the wire through the Foamex.

(https://i.imgur.com/1GuJyF9.jpg)

At the bottom end, I decided to add a thick hunk of Foamex to provide a solid-looking base for the rack that will be painted to look like a part of the armour.

By adopting this approach, I know I can build the grenades separately, paint the rack separately and assemble them once the armour is ready.

Regarding other progress - I added a tight space behind the left chest's to allow me to use an old iPod to drive the chest display.

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

It's a real snug fit - I'll likely add a small strap/bit of tape to secure the iPod from falling backwards, although the fit is so tight I really have to wedge my fingernail in the space on the left side to prise it out.

(https://i.imgur.com/j9Z8QLO.jpg)

And in other departments - it's been lots and lots of snaps...

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

(https://i.imgur.com/5V5iIZr.jpg)

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

I'll likely be supplementing the snaps on the shins with a strip of central velcro and, if necessary, hidden elastic strapping that goes in through slots in the flightsuit calves.

(https://i.imgur.com/Yvyx9oG.jpg)

The backpiece had a bit more refinement with some grey epoxy putty (since it was easier to mould to shape with my hands than P38) and I've added snaps at the bottom to stop it from lifting...

(https://i.imgur.com/4ZkC3Bx.jpg)

Regarding attachment at the top, I'm going with Reyn's suggestion from the other week - drill the neck piece and the top of the back piece and attach them loosely with a leather strap so that the back piece rests on the shoulders and has a non-rigid connection to the neck.

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

...and to give the kidney plate a bit more interest from the back view - some trauma plating, made Swarzily asymmetrical with a couple of pieces of Foamex:

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

Next job is adding masking tape to all those snaps, giving everything a spray so it's back to a nice even metal, and in the background building the grenades for the left thigh.



Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Feb 01, 2016, 03:14 PM
Very nice  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Feb 01, 2016, 03:38 PM
looking good ...hope it all works as planned
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Feb 01, 2016, 04:03 PM
Wow, that's some great work vod!!   8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Feb 05, 2016, 07:23 PM
Just wow.
Title: Re: Armour Planning & WIP for 2 of us
Post by: capnsmirk on Feb 06, 2016, 04:57 AM
Excellent work Vod! I haven't seen many shots of fastening techniques as yet(new kid on the block), thanks! Also i want the updates ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Feb 06, 2016, 09:12 AM
AWEGASM  :o :o :o
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Feb 06, 2016, 09:45 AM
looking good
Title: Re: Armour Planning & WIP for 2 of us
Post by: Jalkaryr Jag on Feb 06, 2016, 09:53 AM
looks amazing! :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 15, 2016, 03:48 PM
Thanks folks!

Well, glacial progress on the kit at the moment as we're in the final race-to-the-finish work-wise for our new videogame. (http://www.threefieldsentertainment.com/dangerous-golf/)
But, pleased to say that all the kit has been sprayed silver and sealed with clearcoat in advance of painting and attaching it all.
Since I'm limited on time lately, I've been doing small fixes and additions - first up - building the 'grenades' for the left thigh...

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

PVC pipes.  The red pieces are actual the tops from washing up liquid bottles - I was rooting around for greeblies and noticed that out-of-context and closed these would make pretty decent-looking switch-like ends for the grenades.  The ribbing on the smaller two pipes is some detail from some large plastic milk containers - I cut around them and with a little heat, wrapped them around the pipes. 

Other small raised panels are more plastic from the milk containers, cut square, corners rounded off and details added by scoring lines in it and punching nice circular holes in it with a paper hole punch.

The large recessed button on the larger pipe is simply a bottle cap, and the clip assembly is a piece off a plastic trouser hanger (remaining from the bits that I made the 'grenade rack' from), a Foamex shape and a screw...

(https://i.imgur.com/uUnSkW6.jpg)

Sprayed up silver and lined up - I'm quite pleased with the results, considering it's just PVC pipe and things out of the recycling. 
Looking forward to getting the time to paint everything and weather it all.

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

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

(https://i.imgur.com/M8EFwcV.jpg)

Feet-wise, I've just about finished the boot armour.

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

Decided to use Chicago Screws to attach the armour - with the front pieces I decided to heat form a few bits of flattened out PVC pipe to add strength to them (learning from how well it performed on strengthening the knees) and attached them using 2-part Epoxy and a couple of screws, punching holes in the PVC to glue the screw heads between the Foamex and the PVC.

The heel armour I decided to add as I noticed the boots had a very subtle logo embossed into the leather.  Since I was making these to fit, I chose to push the Chicago Screws through the Foamex and countersink and fill over the head.

The thing that guided the design of the boot armour for me was trying to make it flow with the existing shapes and lines on the boots - the trauma plate across the top of the foot follows the same lines of the leather underneath and, as you can see, I made both pieces of armour so that they shaped to the elastic  and drew an imaginary curve along the line of the bottom of the front armour that the bottom of the heel armour then flows into.

Have worn the boots for a few hours - the Chicago Screws do press a little into my foot - when it comes to final fitting I'll be stealing a bit of Jayne's old yoga matting to cushion the heads and then wear them solidly around the house for a few days before committing to any kind of trooping in them!

Finally, made a start on my girth belt.  10m of olive green paracord.  Having studied a lot of the tutorials out there I decided that although it might be quicker using hot glue it wasn't for me (I guarantee I'd burn my fingers at least once and would be cursing trying to get the paracord to 'take' the glue) so I adopted the following...more organic approach...

(https://i.imgur.com/UWAIU3T.jpg)

I measured my waist and then cut a piece of card half that distance, tightly wound 7 strands around it and using a large needle sewed the strands together.  I used a 'Z' type stitch - straight through the line of threads and out the other side, stitch straight back through them in the opposite direction, then make a 45 degree stitch across and then two perpendicular stitches before going diagonal again.

Quite therapeutic and I now have 4 small 7-strand belts with hidden stitching that I intend to cut to size and then stitch together to make the whole belt.

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

...and that's the update for today.  Girth belt hopefully completed soon and in the background scribbling tons of ideas for colour schemes (seriously, deciding on one is the hardest part for me) especially since I've now realised that my intended kit is actually only going to be one sidearm and a breaching charge away from an Assault Brigade kit...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Feb 15, 2016, 08:13 PM
I so wish I could make to Celebration London to see you two walking around in these beautiful kits.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Feb 16, 2016, 06:06 AM
Grenades are a work of beauty. I expect nothing less  :P

The Mandos will be ruling Celebration with all these kits out there
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Feb 16, 2016, 08:38 AM
You have an incredible eye for greeblies, vod. Great work!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 17, 2016, 02:17 PM
Thanks again!

Havelock - we'll be doing our best to commune with you via the Force to have you their with us in spirit
Kavryn - my greebly tip - take everything apart that goes into the recycling and keep anything that's cylindrical (amazing how many things are the same size and fit within one another) or looks odd.  Then, scatter the whole lot around while you're building and constantly try to see if you can fit things together.  Oh, and plastic coathangers...

Been playing around in Photoshop experimenting with colour schemes - would this look sufficiently 'urban' for the  267th - I'd rather not go 100% grey, and I rather like the idea of getting in that Swarzy off-white/cream colour that the Rebels have in their outfits...

(https://i.imgur.com/9NpOHOK.jpg)

Whaddayareckon, folks (thinking red oxide primer under most things, the purple as an undercoat to the green, grey primer under the gaunts)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Feb 17, 2016, 02:51 PM
Looks groovy here and extra swarsy!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Myra Tiin on Feb 17, 2016, 03:43 PM
The color combination is just epic and unique.

I wanna see this coming to life :D
You have a real attention to details and manage to get them right.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Feb 17, 2016, 05:09 PM
I love it man. As someone who now has to change his colour to brigade I highly recommend you PM the offensive brigade marshal to check with them. Better safe than sorry.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Feb 17, 2016, 05:43 PM
If it's good with the Brigade Marshall, then I think you're good to go.  It's awesome regardless.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Yogi on Feb 18, 2016, 09:23 AM
This is one killer build!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 18, 2016, 06:14 PM
Thanks all!
Absolutely, Kyri - want to learn from your experience. Have PM'ed and posted to the Brigade boards (twice) - hoping to get some kind of reply soon
Hope everyone's having a great day/evening/night wherever you are!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Feb 19, 2016, 05:21 AM
If you can't see the BRL for Urban assault here it is as a copy:

URBAN ASSAULT
Armor Requirements
•Armor - Medium coverage (with some additional parts if desired). This includes the minimum of boot, shin, knee, thigh, groin, torso/chest, shoulder, back and gauntlet armor. It is heavily recommended the primary armor color be a tone blending in to urban/industrial environments (black, grays, dull white, brick red, etc.). Weathering and other damage is also highly recommended and must be consistent with operating in an urban environment (ie, no claw marks, no 'sun faded clothing', etc).
•Helmet - Helmet must fit the helmet of Era specific CRLs.
•Shoulders - Shoulder armor should be low profile. Pauldrons, while not encouraged, are allowable in addition to, but not in lieu of shoulder bells.   Submission pics must include shots with and without pauldron.
•Backplate - A back plate must be used. A cape or back pack may be used in addition to but not in place of back armor. If a cape is used it must be limited to a Boba style shoulder cape made out of a moderately heavy material that would not get caught on protrusions.
•Backpacks/Jetpacks (optional) - Should be of a low profile design. Jetpacks should be along the lines of the Jango arena pack.
•Cod - Codpiece or Soft Cod / Armored Loin Cod. Loin Cloths to be taken into consideration on a case by case basis, and only with extremely strong supporting reasons why the required piece should be waved.

Weapon Requirements
•Primary weapon must be a carbine, short rifle, or "shotgun" style weapon. No sniper rifles or heavy weaponry.
•Pistol/sidearm required as a secondary weapon.

Required Accessories - These Accessories must be prominently displayed on the Urban Assault kit.
•Three grenades of some sort.
•At least one of the following "breaching" devices:
◦Breaching charges-explosives that may be attached to walls/doors to facilitate entry into a structure.
◦Breaching tool-some sort of hand held tool to assist in the opening of locked doors/windows/hatches.
◦Electronic lock breaking device-some sort of device used for interfacing with and over-riding electronic locks.

Optional Additional Equipment:
•Additional "trauma plates" on top of chest plates.
•Flame thrower. Can be gauntlet or weapon mounted.
•Combat knife.
•Weapon mounted grenade launcher.
•Tactical light on weapon.
•Tactical webbing on armor.


If you keep to the above and also the CRL's of normal mercs apps you should be fine  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 20, 2016, 09:37 AM
Thanks buddy, much appreciated!  (And thanks all for your advice and kind comments)

Yep - I reckon I'm en route to building to all that - the only things in my Mando's inventory I haven't got in-progress are a breaching charge and a secondary weapon for that side holster.

Want/need to get OM yet obviously, but didn't fancy hitting Kyri's colour problem where he's having to repaint his entire kit.  (As much fun as it is to paint a kit, I'd rather try the once!)

As to "primary armor color be a tone blending in to urban/industrial environments (black, grays, dull white, brick red, etc.)." - I'm hoping my use of grey, very dark grey and an off-white (that oaty light brownish tone that is all the way through Star Wars) fulfils that requirement. 

After all, this is a canon urban environment and I'm hoping that my Mando would blend in here okay...
(http://www.endorexpress.net/wp-content/uploads/startours-coruscant.jpg)
 ;D

Thanks again!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kavryn Falco on Feb 20, 2016, 06:37 PM
I'm not a brigade member but I feel like someone would have said something by now if it wouldn't work. Personally I think it's just fine - if you're concerned just weather it up real good  :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Feb 20, 2016, 07:14 PM
It's all good bud. Don't be afraid to include dashes of blue and purple in your colour scheme, cool tone urban shadows have that tinge to them  ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Feb 20, 2016, 11:11 PM
I've gotta say that after sitting and reading your thread for a total of three plus hours today I am extremely impressed with your entire build Vod. You're showing advanced skills that will be very beneficial to your clan and the Mercs. Amazing helmets builds and thanks for furthered motivation for me to get my Shebs in gear and make my stuff that much more amazing!

Also I've bookmarked this thread because you've got me talking about you and have given me further motivation!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 22, 2016, 01:41 PM
Aw shucks, thanks guys.  Bowfanny - that means a lot - I hear awesome things about your kit so that's much appreciated - especially since I'm basically making this up as I go along and drawing on the hours of model-kit bashing I did as a kid in the 1970s!

Progressing on girth belt and when I get spare minute, will tweak colour palette - been chatting to Ashen about it - I think I'm going to work some of the purple out of the gaunts by swapping in some dark grey.  I think weathering should do the rest of the work.


Update:

(https://i.imgur.com/jvZdf8X.jpg)

So that's the plan - pulled down the purple!

In other developments...

Well, lots of Netflix over the weekend saw me finish sewing the strips of paracord together

(https://i.imgur.com/QrrS1kg.jpg)

And then I lined up the 10m of paracord up against my ammo belt and found...

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

..that it was barely thick enough to poke out either side of the belt.

I considered buying another 5m of paracord and then had another idea - a quick consultation with Kris (Jasra) confirmed that this wouldn't be a problem...

Split the big strip into two...

Glue some Velcro strips...
(https://i.imgur.com/POwT1Y1.jpg)

And then attach to the inside top and bottom of the ammo belt...

(https://i.imgur.com/2T9rjyO.jpg)

(The illusion works and it means that there's one less uber thick layer around my middle!)

Next step is to fake a closure at the back, so some card, some stitching, staples and loads of Evo-Stik glue sees me at this point...

(https://i.imgur.com/Bp78kZI.jpg)

Final step is to cover with pleather in a convincing fashion and make Jayne's girth belt too!

Interestingly - the green paracord for my belt has quite an open weave and so when stitched compacts down quite a lot.  I've already begun stitching Jayne's paracord - that has a much tighter weave and will, for the same number of strands make a much deeper belt.



Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Feb 23, 2016, 04:48 PM
Very nice, as always.  I love watching your work-arounds.  Always so creative and effective.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Feb 23, 2016, 06:06 PM
Nice thinking on that mod to save yourself work!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 24, 2016, 10:41 AM
Thanks!

Here's how it turned out...

It sells the illusion for me...

(Discovered that if I always glue pleather in over itself it's really easy to hide the edges that show that it's material.  Also, to break up big shapes - I simply cut a couple of strips, glued over their edges and glued them vertically around the big panels = simple detailing for about 2 minutes work!)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4559_zpslunf1nou.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4559_zpslunf1nou.jpg.html)

(..reminds me need to put a bit of stitching on the left hand panel where it attaches the rope belt - doesn't need it, but it's a little bit of cosmetic detail that fakes that this is a handmade sewn piece, not a cereal packet, staples, glue and all manner of dodginess creation!)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4560_zpssrydjr8s.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4560_zpssrydjr8s.jpg.html)

With back piece attached (needs painting up so it's not just silver)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4561_zpsgcyer6hv.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4561_zpsgcyer6hv.jpg.html)

A couple of snaps to secure it in back there...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4563_zpsqzxgvsbp.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4563_zpsqzxgvsbp.jpg.html)

(Must now stay on low-carb diet - there's very little give in that belt = incentive to keeping Mando Tough all the way to SWCE!)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Feb 24, 2016, 10:59 AM
Beauty job! Mandos always find a way.... :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Feb 25, 2016, 05:23 AM
Very clever workaround, impressive belt!
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Feb 26, 2016, 01:11 PM
great work on the belt and love the clip idea to help hold it together  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kurshi BeJahaal on Feb 26, 2016, 07:33 PM
Seeing this thread makes me want to stop doing what I'm doing and redo my entire kit. Wow. I love your attention to detail.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Feb 26, 2016, 07:36 PM
Seeing this thread makes me want to stop doing what I'm doing and redo my entire kit. Wow. I love your attention to detail.
It's definitely a good example of how to do it the right way Vod!

Simorph,
How did you build your gauntlet forming blocks?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kurshi BeJahaal on Feb 26, 2016, 07:45 PM
It's definitely a good example of how to do it the right way Vod!

You've got that right. I guess it's a bunch of lessons learned on this first kit right now. I have just not been physically able to make anything look as good as I've envisioned it to look. Hopefully V2 (whenever that may be) will be cleaner and look a lot more like this!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Feb 26, 2016, 08:10 PM
You've got that right. I guess it's a bunch of lessons learned on this first kit right now. I have just not been physically able to make anything look as good as I've envisioned it to look. Hopefully V2 (whenever that may be) will be cleaner and look a lot more like this!
I'm thinking the same but version three for me!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 27, 2016, 05:51 AM
Simorph,
How did you build your gauntlet forming blocks?

Here we go....hopefully the diagrams are self-explanatory.

1, But basically, grab the WoF template you're building to - cut out the curves and the template for the inner shell, measure the length of the shell

2. You need to create a trapezium-shaped base where the curves are centred opposite one another and where the diagonal length between their ends is the same as the length of the shell

Cut the base out, tape the curves to it and then fold them up 90 degrees

3. After that, put in a middle support (yellow wedge shape) that connects the apex of both curves (I made a rectangle of card, secured that, then cut the diagonal)

Finally, cut out the WoF template shell and wrap it over the form, starting at one side and carefully bending it and hot gluing it in place (I put little pieces of folded card in) as you go

(https://i.imgur.com/euZz25p.jpg)

One gotcha to be aware of - be careful of the thickness of the card - you want to make sure that the outside of the WoF template shell aligns with the edge of the curves - otherwise your form will be too big

Hope that helps!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Feb 27, 2016, 01:33 PM
Here we go....hopefully the diagrams are self-explanatory.

1, But basically, grab the WoF template you're building to - cut out the curves and the template for the inner shell, measure the length of the shell

2. You need to create a trapezium-shaped base where the curves are centred opposite one another and where the diagonal length between their ends is the same as the length of the shell

Cut the base out, tape the curves to it and then fold them up 90 degrees

3. After that, put in a middle support (yellow wedge shape) that connects the apex of both curves (I made a rectangle of card, secured that, then cut the diagonal)

Finally, cut out the WoF template shell and wrap it over the form, starting at one side and carefully bending it and hot gluing it in place (I put little pieces of folded card in) as you go

(http://i725.photobucket.com/albums/ww258/simorph/Untitled-2_zpspm0lytvt.jpg) (http://s725.photobucket.com/user/simorph/media/Untitled-2_zpspm0lytvt.jpg.html)

One gotcha to be aware of - be careful of the thickness of the card - you want to make sure that the outside of the WoF template shell aligns with the edge of the curves - otherwise your form will be too big

Hope that helps!

Beautifully explained Vod. It makes sense to me.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 01, 2016, 02:54 PM
No problemo, Bow - glad to be of help!

So...this is how the boots turned out...

(https://i.imgur.com/bgBN9Dm.jpg)

Still need lots of painting and weathering, some padding putting over the Chicago screwheads on the inside (although they're still pretty wearable without it) and a method of gently securing the top of the foot armour because I make a clopping sound with my left foot as I walk about.   I'm still debating some kind of toe spikes (because why not?) 

With my girth belt done, I set about making Jayne's using a similar method...

About 7 strands per piece - stitching through them with a zig-zag 'Z' type stitch...

(https://i.imgur.com/vig6Er0.jpg)

Then all 4 strands sewn together...

(https://i.imgur.com/yAc8QHM.jpg)

The much tighter weave on the mauve paracord meant that the cord didn't compress nearly as much as it did on the one for my belt.

So I didn't have to do the fancy workaround (see my girth belt here (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1514228#msg1514228)) for Jayne's belt...

(https://i.imgur.com/vHHhWq6.jpg)

Two rectangular cardboard panels folded in half, the cord ends pushed in about an inch and then sewn through with thread to secure the card to the paracord.
I then pushed heaps of EvoStick Impact Adhesive inbetween the cardboard panel sandwiches to glue them together, to stop the paracord ends from fraying and gluing them inbetween the card.
Then I laminated the two panels with pleather folding it so that any edges would be hidden on the inside of the belt.
And finally did a blanket stitch down each side to secure the pleather to the card to the cord and give a nice bit of edge detail...

(https://i.imgur.com/Z6Avtoj.jpg)

That done, I decided to make a final closure with Velcro, and glued some strips of pleather vertically around the panels to add more detail...

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

Two girth belts - sorted!

I then spent the weekend learning how to use a sewing machine (amazed at how easy it was, to be honest) - first project was making a neck seal...

(I used Sahi's NeckSeal Tutorial (http://mandalorianmercs.org/forum/index.php?topic=28084.0) for inspiration and used a t-shirt as a guide for how to cut the shapes for the 'skirt')

(https://i.imgur.com/aP3KkWy.jpg)

(https://i.imgur.com/8oiKA66.jpg)

...a few bits of wonkiness on that curved hem, but that's going to be hidden out of sight - quite pleased though how it turned out all-in-all.

Finally, I've been working out how to fit knees...

I bought some cotton canvas webbing (since I know that if any of it shows it'll meet the CRLs) and some plastic webbing grips...

(https://i.imgur.com/67q9Ywc.jpg)

I found that if I removed the grip portion and cut off the sides, I got some sturdy slimline plates to screw the webbing to the insides of the knees.
(Learned from the Internets that to seal the ends of cotton canvas webbing you only have to dip the ends in CA/Super Glue - it did the trick and as a nice side-effect gave the screws something much stronger to grip into)
Was keen on doing something like this as it means that it's really easy to take on and off the strapping while painting, weathering, repairing, etc.
The straps secure themselves with Velcro at the back - I may hide them inside the flight suit a la Jango, but being black and of a CRL-friendly material the same stuff works for Jayne's kit (which will have black leggings)

In addition, I've taken a leaf out of Mr Reyn Vok'Chi's book - and made some small foam pads to sit inside the kneecap.

(https://i.imgur.com/bICiOs7.jpg)

These are little black cloth pouches that have bits of foam inside them.  Snaps secure them to the insides of the knees, Velcro on the other side will attach to flight suit.

This has the dual purpose of securing the knees at the front while giving some extra padding.

While doing this I had a go at securing the snaps using a different method - screws!

(https://i.imgur.com/aUdu6o6.jpg)

Much easier than all that epoxy and Foamex sandwiching.  I did find that on the thinner parts of the kneecap I could screw the screw in as normal until it was just about to poke out the other side, unscrew it, cut off the tip of the screw and then attach the snap with the cut-down screw.

I absolutely thrive on learning new stuff and this project never stops teaching me new things!

In other news - sounds like my colour palette/plan will be okay for the 267th Urban Assault, so if this kit ever goes OM I won't be having to repaint for the brigades.

Getting quite excited now - I finally have a colour plan so I may start painting my gauntlets, and possibly knees at the weekend because I'm running out of things to build/attach to other things!
Title: Re: Armour Planning & WIP for 2 of us
Post by: capnsmirk on Mar 01, 2016, 03:58 PM
Siomorph your kit and your explanations of your processes are excellent! Your girth belts look top notch too btw, did you have any issues sewing through the combined layers of materials when you were ready to attach the velcro?
Title: Re: Armour Planning & WIP for 2 of us
Post by: eqdizzle on Mar 01, 2016, 04:10 PM
This is impressive work, vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 01, 2016, 04:13 PM
Thanks Cap'n! (and Eq...or do I call you Dizzle?  :D)

On the sewing point - not really - just patience, a strong needle and I bought thread that was designed for heavy duty wear.

I must admit, the needle is slightly bent now - more like a surgeon's one - but TBH that makes the sewing easier.

I did have a pair of needle-nosed pliers on-hand when things got tough/where the needle wasn't sufficiently long enough to pull clean through all the layers.

Glad everyone likes the way I'm presenting this - I've learned from reading everyone else's WIPs so I'd like to give back, share my fixes, workarounds and also get suggestions along the way.
Title: Re: Armour Planning & WIP for 2 of us
Post by: eqdizzle on Mar 02, 2016, 12:17 PM
Thanks Cap'n! (and Eq...or do I call you Dizzle?  :D)

I've been called worse!!

 :laugh:
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 08, 2016, 01:48 PM
Okay folks, an update from me.

With the paint plan (with the red-purple gauntlets) being given the thumbs-up as suitably "Urban Assault" from the folks in the 267th I finally decided to get the paint job started.

So, I decided to start with...my Gauntlets...

Photo-heavy post but I'm getting so much good feedback from everyone about sharing this stuff I figure I'm going to 'go big or go home' and give you more images.

The same thinking can be applied to the level of masking damage I've done on the gauntlets too...

The gaunts have been sitting on the shelf with 2 coats of black, 2 coats of silver, 2 coats of gloss clear coat and a rub-over with Rub 'n' Buff silver for a few months now.

So first up was masking out the silver parts - I used a combination of regular and precision masking tape based on how fiddly the area was to get to with mostly nozzles and barrels getting the masking tape treatment so they'd stay silver.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4579_zpsoygbx3lz.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4579_zpsoygbx3lz.jpg.html)

To save paint and make the insides as neat as the outsides, I decided to mask off a few blocks in the interiors.

I decided that the front outside edges of the flamethrower box would have taken some serious damage, so I streaked on a heap of masking fluid, and, with a blast of hairspray from the front threw on a little salt to complement the masking fluid.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4580_zps10emukpd.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4580_zps10emukpd.jpg.html)

I decided to keep the inside of the area where the LCD screen sits masked off, as well as giving the tube that will go on the outside of the right gauntlet a bit of a paintjob, masking off both the front and back so they'd stay metal...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4581_zpsjiftvcll.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4581_zpsjiftvcll.jpg.html)

..and again, masking off the insides of the right gaunt.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4583_zpsxjofaeg5.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4583_zpsxjofaeg5.jpg.html)

Having destroyed several brushes now I've found that using a Q-Tip is perhaps the best way to apply masking fluid to these props.  When painting watercolours a brush and soapy water is all you need, but I've found that the long time it takes to do the masking here means that the brush soon disappears into a big rubbery blob within minutes.  For masking out the smaller details, a brush works, but for damage chipping Q-Tips are my new best friend.


To complement the outer right gauntlet - a spray of hairspray and a sprinkle of salt thrown from front to back...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4584_zpsgtmh9ksx.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4584_zpsgtmh9ksx.jpg.html)

I also wanted to add some interest to the undersides of the gauntlets - so, imagining scenarios where my mando would be crawling across rocks, climbing over the edges of walls, etc I decided to put a real heap of effort in scraping the living poodoo out of the front of these...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4587_zpsvzw2byho.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4587_zpsvzw2byho.jpg.html)

Here, I slathered on the masking fluid, heavily on the front edges, thinning out around the halfway point up the arm.  Again, heaps of salt and hairspray on top biasing it to the front of the gaunts.

Because the missile tube would naturally get scraped to bits by multiple firings, plus being caught many times when missiles were loaded, I added a lot of faux scratches to this area - streaks along the length of the tube and extending out over the back of the gaunt...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4589_zpsqwlu298q.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4589_zpsqwlu298q.jpg.html)

With everything masked and the masking fluid dried I hit everything with a grey primer...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4593_zpsc8rqj6fw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4593_zpsc8rqj6fw.jpg.html)

Alarmingly I did notice some orange-peeling of the paint...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4594_zpsyxslip8b.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4594_zpsyxslip8b.jpg.html)

It seems likely that this was caused by me not washing the gaunts prior to masking - the weeks of sitting on the shelf and handling must've been enough to put a few bits of dust and grease onto the top surface - enough to cause a few reaction spots...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4595_zpscppmqsyw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4595_zpscppmqsyw.jpg.html)

Then came the process of de-masking the whole thing...(Note the small piece of plastic that broke off as I got a little over-enthusiastic..)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4597_zpsrizh9mft.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4597_zpsrizh9mft.jpg.html)

Whether it's the age of my masking fluid, I don't know, but I was slightly alarmed that it lifted the silver paint on some of the sharper edges, taking it back to the black primer - no worries though, I'll simply touch up with silver acrylic and Rub'n'Buff prior to weathering.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4598_zpsg3nunndg.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4598_zpsg3nunndg.jpg.html)

As I said above - I REALLy went for it on the gaunt's undersides - and I LOVE the way that the salt breaks up the painted strokes of the masking fluid so you really get the sense of years of erosion...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4600_zpshfo7obli.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4600_zpshfo7obli.jpg.html)

Little details - I edged the inside panels with masking fluid.  And, made a conscious effort to weather the gaunts harder at the business end than at the back of them.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4601_zpspalaviep.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4601_zpspalaviep.jpg.html)

Similar treatment on the right gaunt...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4602_zpst3jf11wq.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4602_zpst3jf11wq.jpg.html)

Then it was back over with the masking fluid and tape, and blast everything with the top coat...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4606_zpsnozstpwu.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4606_zpsnozstpwu.jpg.html)

I'm using KOBRA's range of low pressure tagging paints - they have some fantastic colours and do play nice with the Hycote car paints I've been using.  They are quite thick though, so I'd only recommend them for top coats - they give the appearance of a heavy enamel paint.

One coat of KOBRA is plenty as it has astonishing covering and although it's pretty quick to touch dry it does stay slightly 'rubbery' for a few hours after spraying (in fact it will pick up fingerprints if you handle it with any amount of pressure.)

To work around that, I let the paint dry in the garage for a couple of hours, then brought it inside and laid it on a sheet of MDF over the radiator for a few more hours to harden off.

That seems to get me to the point where the paint is hard enough to handle, but soft enough to make masking removal possible without really scrubbing at it.

So here's the current state of play after masking removal and a good wash with soapy water.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4608_zpsdlysbuih.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4608_zpsdlysbuih.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4609_zpswenweedd.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4609_zpswenweedd.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4611_zpsmnstblhz.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4611_zpsmnstblhz.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4613_zpspvoghgch.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4613_zpspvoghgch.jpg.html)

Silver highlights need painting back on pre-weathering with washes, and I have a bunch of other minor tweaks to do, painting cables, putting a few different metal finishes on the silver parts...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4614_zpsqty9jjf1.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4614_zpsqty9jjf1.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4615_zpsqhgiqf4a.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4615_zpsqhgiqf4a.jpg.html)

With those on the go, next on the production line is knees....

Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Mar 08, 2016, 02:57 PM
I'm sure I'm not the only one to say that I'm not surprised that these have come out stunning! As always love the work, the colours weathered through look awesome!  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Mar 08, 2016, 05:14 PM
Cracking job as ever  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Mar 08, 2016, 05:30 PM
As always you're moving along swimmingly Vod. That cracked off piece will give your gaunts that extra bit of character!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Mar 08, 2016, 07:32 PM
So. Freaking. Amazing.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Aden Banto on Mar 08, 2016, 08:36 PM
The amount of work you put into weathering those gaunts is pretty impressive
Title: Re: Armour Planning & WIP for 2 of us
Post by: capnsmirk on Mar 09, 2016, 02:46 AM
What i love the most is seeing in depth the application of masking and salt weathering, the gaunts look sweet btw. This is a process I've been mulling over in the back of my head as i edge closer to being ready to paint. The Kobra tagging paints are a graffiti spray paint yeah?

The way you have documented your work so thoroughly really is a gift to the community, ori'vor'e vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 10, 2016, 04:48 AM
Yep - Kobra (http://kobrapaint.co.uk/page3.htm) is a tagging paint.  I've heard a few of the Vok'Chi mention that they're not a preferred brand as they are quite thick, but the range of subtler colours in their Low pressure range makes up for it.

As I said above - I found them to be touch dry quite quickly but it will be a few more hours before you can handle surfaces without leaving a fingerprint - my solution was to rest items on MDF board near the radiator. But yep, really thick - more like a gloss woodworking paint - the low pressure cans mean that you can get really accurate while spraying so it's not too difficult to avoid drips/overloading a surface but I've found one carefully applied coat is enough to cover anything. (To get the masking fluid/salt off, I've had to use a plastic pan scouring sponge for the majority of the surface.)

 (Knees in progress- just sprayed Kobra green over Hycote red oxide primer and within a stroke the red had been completely obliterated.)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 12, 2016, 09:32 AM
Just drew up this diagram in response to questions about what 'Rolling' the edges of armour actually meant.  Here's my take...

(https://i.imgur.com/VnhsA8J.jpg)

Need to post in-progress pics later this weekend - knees ready now for grime and dirt washing
Title: Re: Armour Planning & WIP for 2 of us
Post by: Myra Tiin on Mar 12, 2016, 10:18 AM
This weathering technique is so cool, i'm saving it. Somewhere.

And I also think that Graffiti spray paint is awesome for painting armors :) I'm using Montana Colors (94 series, wide range of colors, low pressure, has a little smell of vanilla and dries in less than 15 minutes :) )
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Mar 12, 2016, 01:00 PM
That diagram is going to be so incredibly helpful to so many people.  Me included.  Thank you!   ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 13, 2016, 04:57 PM
You're welcome - so difficult to describe, but dead easy to explain in a diagram.

Anyhoo...here's how the knee painting went...

Masking fluid, hairspray+salt (plus a few twists of black pepper, because I picked up the wrong grinder!)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4616_zpsha38dbqo.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4616_zpsha38dbqo.jpg.html)

Red oxide primer...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4617_zps7wg8sxv5.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4617_zps7wg8sxv5.jpg.html)

And then green and the dark greyish purple...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4639_zpskekmjaxw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4639_zpskekmjaxw.jpg.html)

That's where they are now - grime wash + final seal to be done later...

Here's how the gauntlets ended up - I used two different types of Tamiya paint - Chrome Silver - which I used to paint over all those black corners that had been revealed when the masking came off, and Titanium Silver - which is a bit more yellowish - this I used to highlight things like the keypad,
missile cone, etc.  A few places were hit with some Humbrol Gunmetal Silver.

The intention here being to make the gaunts look as if they're made of numerous parts made from different types of metal...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4635_zpske9r7b75.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4635_zpske9r7b75.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4636_zpsfgm1zevv.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4636_zpsfgm1zevv.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4638_zpsjpvgv0j5.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4638_zpsjpvgv0j5.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4637_zpsppbdinjt.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4637_zpsppbdinjt.jpg.html)

Like the knees, these need a grime wash and sealing coat as well as electronics and some padding.

On the footwear front, I solved the 'clopping' problem I was having where the boot armour was lifting away from the toe of the boot and dropping down, making a clopping sound as I walked...

I attempted to just add a single snap to the toe but found that it unsnapped as the boot flexed when I put it on.  I tried a solution with a piece of elastic between two snaps on the boot and one on the underside of the plate but found that the snap on the plate kept unsnapping itself.

So the final method I solved it - a snap just above the toe that snaps into a piece of elastic, with the elastic screwed into the plate.  This gives the boot plenty of flexibility while moving, putting on, screwing the top snap into the plate means that it doesn't unsnap itself as I walk and the elastic constantly acts to pull the plate down.  Problem solved!

One tip - CA glue ('Superglue' in the UK) applied to the ends of the elastic stops it from fraying...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4641_zpsk8rmboon.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4641_zpsk8rmboon.jpg.html)

Finally managed to get an hour with Mrs P for the first time in a while to start fitting plates.  The first one, likely the most challenging - the back plate.

First Order (no pun intended) was getting the collar plate so it sat high and comfortable right below my neck - a combination of Chicago screws to attach leather strips to the back plate and snaps on the collar plate to make it easy to put on and take off (we tried Chicago screws on both backplate and collar plate, and while they held fine, it did mean that getting in and out of the kit was a bit of an undertaking!)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4619_zpsv82rcqo9.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4619_zpsv82rcqo9.jpg.html)

The backplate, while Reyn and I had spent a lot of time shaping it a few weeks ago, in practice, with belts in place proved problematic.  We found that the lower back was still far too straight and so pulling it down to fit the small of my back meant that the shoulders rose up and created a large gap between the flak vest and the backplate.

So, we bit the bullet, lined the inside of the backplate with foil and hit it with some heat - bending the backplate in the middle to fit the form of my back better...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4631_zpsidajcgyg.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4631_zpsidajcgyg.jpg.html)

This does mean that the bend created a couple of nasty folds, so it's back to the body filler to give this piece some final TLC and hopefully that will be the piece finally finished.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4624_zpsvlbq6pkj.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4624_zpsvlbq6pkj.jpg.html)

Good to get an hour to start working on fitting and especially since I could get Jayne to help out and be an extra pair of hands/eyes since most everything I've been doing lately has been little 10 minute jobs pulled in here and there between work and sorting out family.  Most of weekend spent using new DIY skills obtained during this project to fix my parent's toilet so getting a little Mando time was most welcome!



Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Mar 13, 2016, 05:34 PM
 :o :o :o :o :o :o :o :o :o

That is all
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Mar 14, 2016, 02:24 AM
:o :o :o :o :o :o :o :o :o

That is all

 :laugh: :laugh:

Uh, ditto.  heh
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Mar 14, 2016, 03:10 PM
Youre almost there now vod. Looks amazing
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 14, 2016, 04:23 PM
Thanks - means a lot!

Managed to squeeze all those horrible creases out of the sides of the back piece by hitting it with heat from the inside and squeezing it straight.  A bit of P38 sanded down and I'm about to re-silver those bits - turned out to be less hassle than I'd expected.

Bit of advice from Kris - to put some padding under the shoulders of the flak vest to help the flak vest fill out the space under the backpiece - spent quite some time yesterday with Jayne pulling down on my shoulders to get it to sit right, so this little dodge will definitely help.

Anyhoo, about to grab some spray cans from my stash up here near the computer to nip out and spray the top coat on Jayne's gaunts and the patching up on the back (Cold here in the UK so have chosen to store all my rattle cans inside and give them a thorough shaking in the warm before heading out to the garage to do the spraying)

Have a great evening/day,folks!  Will post new pics as soon as I've got something new to share.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 27, 2016, 09:01 AM
Series of mid-Easter weekend shots as we progress on multiple fronts...

First up - using heat and pretty much squeezing the Foamex into shape got the creases out of the back plate, then slapped on the P38 (ooh, new bottle of masking fluid - to replace the 35-year-old one I finally used up, and some battery boxes to power helmet fans)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4644_zpsffl0pif9.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4644_zpsffl0pif9.jpg.html)

And then a whole bunch of wet-and-dry sanding to get us smooth and sorted:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4645_zpslmzk8kaq.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4645_zpslmzk8kaq.jpg.html)

That done, I leapt in and fashioned a pattern for Jayne's flak vest out of wrapping paper (had ran out of brown paper, so the remnants from Xmas came to the rescue) - surprised myself how much easier it was than I'd expected, with darts pretty much forming themselves when we tried the pattern on.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4647_zpseote8ers.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4647_zpseote8ers.jpg.html)

This broke down to a front like this:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4648_zps0oq6hppg.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4648_zps0oq6hppg.jpg.html)

And a back with an opening down the middle...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4651_zpstrxteknr.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4651_zpstrxteknr.jpg.html)

The whole thing's finished - I just need to get time to take Jayne's photos wearing it - which we'll do when we start patterning templates for her plates.

In the mean-time, cut a couple of custom card templates for Jayne's boots...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4654_zpst3mdj9mz.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4654_zpst3mdj9mz.jpg.html)

Which form to the boots like this - taking what I learned from armouring up my own boots - make the curves match the shapes of the leather - it's easier for positioning and I've found that I end up with plates that look like they're supposed to be a part of the boot...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4655_zpssldm3huh.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4655_zpssldm3huh.jpg.html)

And finally - we spent some time attaching my plates:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4657_zps1ipv3o8d.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4657_zps1ipv3o8d.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4659_zpsa91irqw4.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4659_zpsa91irqw4.jpg.html)

(standing slightly wonkily and making the back look out of alignment...d'uh!)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4667_zps21ogxtjt.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4667_zps21ogxtjt.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4664_zpsl2gieujm.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4664_zpsl2gieujm.jpg.html)

Fantastic to be finally seeing the flak jacket covered in plates, each attached with myriad snaps - a good few hours kitting up, marking snap points, stripping off, hammering in snaps, kitting up again - with Jayne measuring, double-measuring and judging that all the points that were supposed to line up lined up!

Have learned a little more about what's working with the kit - am going to change the snaps on the inner girth belt to something that's easier to buckle up.

Just in the process of taking up the flight suit trousers and attaching shin plates so soon I'll be able to start paint work!


Hope everyone's having an ace weekend.  More pics soon!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Mar 27, 2016, 11:11 AM
The kit is looking amazing Vod. One thing I'm seeing is the spacing around your diamond is slightly off on the topside with the chest plates being closer on the top than at the bottom.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 27, 2016, 12:04 PM
Good catch!

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

And that's why I've found this method of attaching snaps to the armour plates is my favourite...

(https://i.imgur.com/mavr5fZ.jpg)

So much easier to make micro-adjustments.

Thanks!

(currently having a fight with shin plates - refusing to sit right - I'm thinking I'm going to have to add some elastic strapping to pull them into my shins...)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Mar 27, 2016, 12:16 PM
Plates look awesome. As for shins you probably will. What im doing with kai's new gear is sewing a pair of legleggings into her flightsuit and having the plates mount to the leggings and baggy trousers and they all sit well against her legs.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Mar 27, 2016, 01:54 PM
You're looking absolutely bad-shebs, mate.
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Mar 27, 2016, 02:25 PM
i agree. you've knocked it outta da park... outstanding!!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Echo Darklighter on Mar 27, 2016, 10:57 PM
Looking nice, vod!  I can't wait to see this finished.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 28, 2016, 04:19 PM
Cheers!

Well, today finally saw all the pieces come together and be fitted properly for the first time.

Pondering strapping overnight, I revisited the knees.  Because of the fact that I'm attaching my straps with mechanical connections, not glues, it was trivial to swap out the webbing straps I'd put in and replace with elastic.  Removing the soft knee pads from inside the knees I tried the knees on and they fit perfectly, no riding up, sliding down - totally secure.

So, I set about cutting the collar off my flight suit and sewed a couple of fabric sleeves for them (a technique Paul/Reyn Vok'Chi  introduced me to when he came over to help out.)

I decided to keep the snap at the top of the inside of the knee as a locator - I've found over the past 96 hours that the one great thing about snaps is that they make it easy to replicate the same fit over and over.  By attaching the snap at the front inside of the knee I not only get a little security that the knees aren't going to tilt forwards, but I know exactly where the flight suit needs to be pulled down to fit them with respect to thigh and shin plates.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4671_zpsl3qfbcxi.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4671_zpsl3qfbcxi.jpg.html)

I may add some padding back into the knee pads, but having worn them a lot today the only area where I'm getting much pressure is the sides of the knee where the strapping attaches.  If I refine this in future updates I'll post my findings.

And, further to yesterday's small post about attaching snaps to armour - here's the method I'm finding works really well:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4673_zpsmsz5mpgp.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4673_zpsmsz5mpgp.jpg.html)

Take a small self-tapping screw, snip off a few millimeters from the tip so the screw doesn't poke out of the other side, make a small pilot hole in the back of the plate and screw the male part of the snap to the plate.

As with yesterday's minor adjustment - if the female snap on the vest is slightly out of alignment, it's trivial to make adjustments to the plate-side snaps by unscrewing them and refitting.  Then, when you're happy, unscrew, blob in a bit of 2-part epoxy and screw back - that snap isn't coming away!

With the knees sorted and the fabric covered strapping working, I took the same approach with the shins...

Elastic strapping with a sleeve of spare flightsuit material (from the rest of the collar and a front pocket) secured using a plate of Foamex and a couple of screws...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4675_zpsumoyeryb.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4675_zpsumoyeryb.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4676_zpsth5ucqir.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4676_zpsth5ucqir.jpg.html)

And the results - well, here's photos of the kit assembled for the first time with all the proper attachment methods...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4682_zpsr5ddq6pn.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4682_zpsr5ddq6pn.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4684_zpsuiholwmn.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4684_zpsuiholwmn.jpg.html)

Pleased how the straps just blend right into the rest of the suit...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4686_zps13bcan42.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4686_zps13bcan42.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4689_zps4xaeerhu.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4689_zps4xaeerhu.jpg.html)

And one other thing - I also took Paul(/Reyn)'s advice in putting some elastic stirrups into the legs of the flightsuit.

These make dressing so much easier, keeping the legs of the suit in place while you put on the knees and shins as well as guaranteeing that the legs don't separate from the tops of the boots as you walk around.

So a very productive weekend for us - some minor, minor things to finish off (cosmetics on the screws that attach the backplate, a little more material on the shin strap covers - so there's absolutely no chance of elastic showing, a better attachment for the back of the girth belt as the snaps that are there are possible to snap shut but take longer than you'd want to secure in place, sew up some side pockets and tidy up the flight suit neck where I removed the collar.)

Then it's on to painting for my kit and start the template work for the remaining 7 plates for Jayne's kit.

Hope everyone's had a great day - see you all soon with another update!


Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Mar 28, 2016, 04:39 PM
Backplate looks to be lifting more than last you took pics on one side and you've got different height thighs :P But apart from that, looking good.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 29, 2016, 10:33 AM
Thanks Kris - that may be me standing awkward - to get in shot my visor had to be flat with the wall, but we'll check.  Likewise, will double-check the thighs - that may be a slight shift in the material of the cod area of the flight suit that's causing one to appear lower.
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Apr 03, 2016, 03:31 AM
got to say your kit is looking fantastic
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 03, 2016, 11:45 AM
Thanks Spidey!

Righto, so work has been super busy this week (our game (http://www.threefieldsentertainment.com/dangerous-golf/) is almost finished!)

So progress has been minimal.

One thing we learned from all that trying on over the bank holiday weekend was that fastening the girth belt with snaps was really fiddly and difficult, so I'm revisiting it at the moment - repurposing an old belt and stitching it along the middle of the two strips of paracord.  Not fun stitching through those thick layers but I think it'll make getting geared up much easier.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4704_zpsvmiwzaiz.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4704_zpsvmiwzaiz.jpg.html)

And the other thing we've managed (since this thread is 'Armour Planning & WUP for 2 of us') to start templating out my wife, Jayne's plates - here's the first draft...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4703_zpsksnzfdez.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4703_zpsksnzfdez.jpg.html)

(And featuring the completed flak vest in pleather, lined with black cotton, patterned and sewn by yours truly!)

Hope everyone's having a great weekend



Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Apr 03, 2016, 11:57 AM
I always enjoy seeing new updates from you, vod.  Great work, as usual.  Sizing and spacing looks spot on.   :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Apr 03, 2016, 12:01 PM
Yessir you two are going to have afreakingmazing kits once you're both done! Are you going to app them both at the same time or whenever you finish one?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Apr 03, 2016, 12:27 PM
Don't forget to fully get those shoulders down when they're in foamex, and your pouches look to be falling down a little, but otherwise, those plates are looking excellent, well sized and spaced.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 03, 2016, 02:06 PM
Thanks Kris, that's great news! I can finally begin cutting those plates!
As goes app'ing together - I guess it will likely happen around the same time - I've been adopting the 'faster to build two at the same time' which means that we've been developing both kits in parallel. Clearly the learnings from building, sizing and attaching my kit are paying off this time around.
Nearly finished sewing the girth belt upgrade will need a week at work to let my fingers recover!
Title: Re: Armour Planning & WIP for 2 of us
Post by: TVarius on Apr 16, 2016, 11:46 PM
Your work looks amazing, awe-inspiring.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 17, 2016, 09:31 AM
Thanks 'T'!  Much appreciated.

Brief update since work is dominating right now so little bits of progress on Jayne's kit over the past few weeks.

Boot armour finally worked out and attached using snaps:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4731_zpsqsjgdc0n.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4731_zpsqsjgdc0n.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4732_zpsbmgng5sc.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4732_zpsbmgng5sc.jpg.html)

Trying to think of a creative way of hiding the zipper pull without drawing attention to it/making it too hard to zip up the boots:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4733_zpse49rhbo4.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4733_zpse49rhbo4.jpg.html)

Plates are cut, formed and sanded.  Here's our very first tape-them-on test for size along with knees, gaunts and blasters:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4736_zpsjrg5nx5o.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4736_zpsjrg5nx5o.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4737_zpsyttuxxhz.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4737_zpsyttuxxhz.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4740_zpsl5agzsfa.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4740_zpsl5agzsfa.jpg.html)



Working on rough template for backplate:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4743_zpstcdgfje2.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4743_zpstcdgfje2.jpg.html)

Left hand side looks best fit here, so when I get some free time I'm going to take the left hand side, flip it, cut a template and use that to cut the Foamex for the backplate.

Lady Mandos - any advice most welcome here!

Right - back to work for me!  Hope everyone's having a great weekend.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Apr 17, 2016, 12:49 PM
Yay updates!

Love the boot armour!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Apr 17, 2016, 12:52 PM
This is looking great, my friend, as always.  And if you hadn't pointed out the zipper issue and provided a close-up, I wouldn't have noticed.  With as close as the armor is to the zipper, you might be ok with it as-is.  I'm sure an App Team member will be along at some point to confirm or contradict that.   :laugh: 

The only thing I'm really seeing is that her flak vest looks a tiny bit baggy, particularly around the sides.  I'm not sure how much of an issue that might be, since you're still working on the whole thing.  Everything else looks phenomenal, as expected.   ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Apr 17, 2016, 04:02 PM
Si, is that your helmet she's borrowing? As it's very big. If not - you're definitely going to need to beef up the shoulders, add some neck armour/pauldron, add something to the biceps. Basically make her shoulders bigger then they are.

Vest is a little baggy. I'd either tailor it or as it's tucked into the girth and that's causing some of the rucking you could cut it back to be more Boba length.

Boots - run a false leather strap around the boot that fastens under the plate?Or that just velcro's all the way round the back if the plate can't be lifted?

Cod plate also looks a little small - best to have the top of the cod hidden by the girth belt.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 17, 2016, 04:05 PM
Wicked!  Thanks guys for all the kind comments, and thanks Kris for all the advice - most helpful indeed!

Yep, that's Jayne's helmet - if you reckon we can solve sizing with beefing up the shoulders, consider it done!

Thanks again!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Apr 17, 2016, 04:09 PM
I always suggest beefing up first. If it works you're sorted as those parts are usually easier to make. If not, you still have the extra parts to use if you want to.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on Apr 19, 2016, 12:50 AM
I'm with Kris. Your lady is so slender there's an odd imbalance with size. If only the rest of us were so lucky  :D One thing I could think of was that you could maybe make the collar plate a bit wider and trim the space a little between it and the chest plates to give the illusion of evenness ? You could also try to gently taper the bottom of the cheeks so it flows with the rest of tapering you have throughout. You really have your head on straight with everything else. I'm sure you'll figure it out.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 19, 2016, 06:36 AM
Thanks!  (And Jayne'll take the complement - switched to eating low-carb/low-sugar a couple of years ago and the weight fell off! (http://jp2mk.blogspot.co.uk/2015/06/one-year-on.html))

I'm looking at Jay Krayt's kit (http://mandalorianmercs.org/forum/index.php?topic=65328.msg972141#msg972141) for solving this, using the larger left shoulder pauldron from these templates (http://mandalorianmercs.org/forum/index.php?topic=26919.msg375870#msg375870) as a basis since it's based on a Swarzy design - although I'm going to use Foamex/Sintra rather than craft foam.

Crazy-busy this week as we're finalling our game (http://www.threefieldsentertainment.com/dangerous-golf/) but hoping at the weekend to do a little more work on the kit and post an update.

Thanks again, guys - that's really helpful!
Title: Re: Armour Planning & WIP for 2 of us
Post by: GardenGeek on Apr 20, 2016, 11:47 AM
You could always add the second, short boba sleeve on her flight suit too. It might help bulk up her upper arms too :)

As always though- quality kits Vod :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 20, 2016, 04:15 PM
Neat idea!  And it gives us something more substantial to attach the bicep armour too!

(And I get to fire up the sewing machine again, which is always a win!)

Thanks for that!   :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 24, 2016, 01:32 PM
Well, had a fun afternoon building some additions to Jayne's kit...

Here's bicep armour that I designed by referencing the scout trooper armour and re-purposing the existing shoulders.  Following the scout trooper lead, these will likely attach with a black elastic strap (with a black fabric sleeve) and possibly a snap/velcro at the top to guarantee correct alignment every time and prevent them sliding down.

I'm building a couple of greeblies that attach to the outside middle of both of the biceps to bulk them out even more, but sticking them on with tape would've been impossible in this test - suffice to say that the upper arms will bulk out more than this...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0068_zpsxh3w4hs9.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0068_zpsxh3w4hs9.jpg.html)

We also subbed in a small piece of paper in under the existing cod plate to extend under the girth (need to cut and shape that once I've finished posting this update!)

With the helmet on, this means we're hopefully a lot more balanced.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0070_zps9sifuch8.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0070_zps9sifuch8.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0072_zpse4htvudq.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0072_zpse4htvudq.jpg.html)

(And we'll work on a solution for the exposed sports-gear waistband here - the previous photos were taken with the top over the leggings - we're yet to work out which solution is most practical)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_0075_zpsybtcsbe0.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0075_zpsybtcsbe0.jpg.html)

Then came a quick backplate template test...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0077_zpsrvk0dwip.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0077_zpsrvk0dwip.jpg.html)

And finally forming the backplate...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0081_zpsrzikvmke.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0081_zpsrzikvmke.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0084_zpsxr9yazme.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0084_zpsxr9yazme.jpg.html)

Decided to cut a scoop out of the back to make it easier to bend the material in and add a little more character.

Tops of the backplate and the collar align pretty much, so we'll employ a similar system for attaching the collar plate to the backplate as with my kit - a strap that the backplate hangs off.

Thinking that the pauldrons will then snap on (with snaps) to the front of the collar and to the vest, but not to the backplate - so as to allow a bit of movement between the backplate and the pauldrons.

All the plates in these photos are being held on by masking tape so apologies if a few things are a little off between shots, but it feels like we're getting closer.

Hope everyone's had a great weekend - we have - one day of working, and a day off making Jayne's kit and the plan for tonight - finally re-watching TFA on Blu Ray.
Chewie, we're home!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Apr 24, 2016, 05:38 PM
That really helps, nice job. Not too far off now apping in now 8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 24, 2016, 06:16 PM
Sweet! Of course, I had a great teacher in the art of forming back plates... ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Apr 25, 2016, 10:17 AM
amazing how the large shoulder plates add a new look and nice job on the back plate ...really not looking forward to trying to sort mine
 
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 25, 2016, 12:20 PM
Thanks. Backplate isn't so hard if you know about Reyn's trick of adding darts into the Foamex to allow you to curve over the top of the shoulders. If you can do your bends in a methodical fashion, like getting the curve down your back first, then working on the sides, and make bending your sides a matter of making a small adjustment to one side and then immediately doing the same to the other side you'll be able to maintain control over the Foamex and maintain symmetry.
Having someone on hand to even hold it to your back as you do this is pretty much essential unless your arms bend backwards through 540 degrees to allow you to do it yourself!
But yes - the big secret is darting the sides from the shoulder blades up.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on Apr 25, 2016, 03:18 PM
Really like the addition, totally balances her out. God job vod! :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 14, 2016, 05:17 AM
Thanks Laa!

Well, the game I've been working on is nearly finished (out on 3rd June at a very resonable price!) (http://dangerousgolf.com/)  ;D but it has meant that progress on the kits has been a little patchy of late as we've been working lots to make final adjustments and get the game approved by Microsoft, Sony and Valve.

That said, we've not been completely stationary.  And thanks to Thaxos, my forum name change has come through - I've gone Syko...

So, in amongst tea breaks and spare moments, this is what's happened of late...

I fashioned Jayne some bicep armour...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4776_zpsqx48fdtj.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4776_zpsqx48fdtj.jpg.html)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4847_zpsfd8jkc4s.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4847_zpsfd8jkc4s.jpg.html)
And added elastic strapping secured with a Foamex plate and covered with a black fabric sleeve - decided to add some extra bits of sewing detail since I'm getting more confident with the sewing machine...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4846_zps0y9drrg7.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4846_zps0y9drrg7.jpg.html)
And Jayne's entire kit has now been hit with 2 coats of black, 2 coats of silver, 2 coats of clearcoat and I've screwed in all of the male snaps in preparation for fitting - as I've mentioned earlier in this thread, I've found that screwing the male snaps into the armour means that adding snaps isn't an all-or-nothing approach - it's possible to make a few adjustments for minor alignment and then when everything's 100% a dab of super glue makes a more permanent attachment.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4844_zps7ssfizgo.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4844_zps7ssfizgo.jpg.html)
I've also upheld my promise to Jayne - her one condition on allowing me to make her a kit - I've attached a couple of permanent magnets to the earcaps, the purpose of which will be revealed in the fullness of time...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4787_zps5kfscugi.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4787_zps5kfscugi.jpg.html)
And to round things out on Jayne's kit - here's a mockup of the colour scheme we're aiming for.
She really likes the Sabine kit and its styling, so I used that as a jumping off-point - I'll likely use a few different coloured primers across the plates when doing the paint job to get the feeling that, like Sabine's armour, it's made up of a number of differently sourced pieces that have been brought together over time.
(http://i725.photobucket.com/albums/ww258/simorph/jayne%20mandopalettetest_zps0reogdw9.jpg) (http://s725.photobucket.com/user/simorph/media/jayne%20mandopalettetest_zps0reogdw9.jpg.html)

In other news...

I took a few minutes to run up a couple of Boba-style side pouches but have yet to have time to try out a fitting on either of our kits - hoping to attach them to my belts, but that will be conditional on them not having conflicts with my thigh plates.  There's enough loop on them to create a slip-on loop onto the ammo belt and I now know more about how the original screen used Boba Fett pouches were attached than I ever think I wanted to...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4848_zps557uqcrb.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4848_zps557uqcrb.jpg.html)

And I've given all my parts a good clean, gone over all of them with Rub 'n' Buff silver and hit them with clearcoat...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4840_zpspnirhp4p.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4840_zpspnirhp4p.jpg.html)

So today, after almost a year of building the masking process begins on my kit and the Syko Voss urban assault paint job finally begins...
Excited, but a little bit daunted...I'll post with progress updates soon!


Title: Re: Armour Planning & WIP for 2 of us
Post by: forallthemarbles on May 14, 2016, 07:56 PM
This WIP is so good, I don't think I'll ever be satisfied with anything I'll ever build, and I'm not just talking Mando, anything I'll ever build.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on May 15, 2016, 02:48 AM
Youcan also mount the hip pouches on your cod/kidney plate. Using them almost like a belt. Thats what im doing for my partners kit. It frees up belt space for other things.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 15, 2016, 05:03 AM
That's a good idea - my cod & kidney plate are attached to a webbing belt, so as long as I can get the right clearance that should work too!
All masking fluid & salt applied to all plates, helmet through cod hit with red primer...and then the spraycan ran out...c'mon Amazon Prime, Syko needs those legs painting!
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on May 16, 2016, 05:11 PM
all looking very good and love the Sabine style paint scheme on jaynes armour and intrigued as to the magnets on her helmet
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on May 16, 2016, 05:34 PM
Syko,
Once you and your ladies kits are done maybe you consider doing some commisions for people because your kits are that outstanding! I liked your other name too before the change. Lol
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on May 16, 2016, 07:36 PM
Just...as always...WOW!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 17, 2016, 06:41 AM
Oh, you guys...
Never say never - I'd like to learn how to do some casting after I've completed these kits (I'm a serial collector of skills) so who knows...?
And my regular sig on most boards, etc is simorph (SIMon Robert PHIpps) but on arriving here, figured we'd do our best to fit in with suitably Swarzy Mando names - unfortunately Thaxos was a little busy doing his best to get around to applying name changes (I think it took about 10 months!) suffice to say there's a bunch of Vok'Chi who I can only recognise from their kits now that they've all been renamed with things with lots of apostrophes in them! :)

Anyways, update from the weekend:

Red oxide primer all over, using masking fluid (applied with a Q-Tip) and salt weathering using hair spray and rock salt...

(http://i.imgur.com/unjbRac.jpg)
(http://i.imgur.com/eUBcLrf.jpg)
(http://i.imgur.com/tlxwHqK.jpg)
(http://i.imgur.com/4PlCOcH.jpg)

And then there's the plates...

...same method - I've discovered that a plastic pan scourer seems to work best for getting the masking fluid/salt off (have rubbed fingers raw, tried 2000 grit sandpaper and pencil erasers but this, plus warm soapy water does the trick best for me)

The side-benefit is that it rubs back some of the paint too - so you'll get subtle variations in the paint all over and lots of micro-scratches and abrasions - really beds the whole paint layering in nicely...

(http://i.imgur.com/dA2xA4g.jpg)

Remembered to make a big deal of those physical damage 'blast points' on the plates where I hit them with heat gun+aluminium foil:
(http://i.imgur.com/buwOwmM.jpg)

And with leg plates, I lined up the knees with the leg plates and did my best to mimic the flow of the chipping/weathering through the knees.

(http://i.imgur.com/iNewDKz.jpg)

Then onto grey on the helmet....

(http://i.imgur.com/rKKvy22.jpg)
(http://i.imgur.com/386PVkg.jpg)
(http://i.imgur.com/Dm9Wl7g.jpg)
(http://i.imgur.com/DvWf88A.jpg)
(http://i.imgur.com/M2vMubb.jpg)


And then cheeks and back with the ivory/cream colour....

(http://i.imgur.com/0QwdMD8.jpg)

(http://i.imgur.com/VUYDe9V.jpg)

Disappointingly some of the masking tape I was using to mask the front of the t-visor was a bit too aggressive and lifted a lot of the primer/grey revealing a heap more silver....thankfully I've yet to paint this area purple and because I have been documenting this with all these pics, I can see where I want to take it back to.  Lesson learned for masking the rest of the kit!

(http://i.imgur.com/lmXzzwW.jpg)

Inbetween these, I've started painting up the grenades and parts for the left-thigh...

(http://i.imgur.com/dM1ZeDN.jpg)

Glad to see that these are starting to look suitably Swarzy - I intend to paint over some  of the silver with a few different silver coloured paints so there's some subtle metal colour variation in them so they don't look like they're one flat silver colour.

Next up - mask up the dome for the ivory/cream section of that!
(Oh, it's been brilliant to finally have a long weekend off to really get back to finishing these babies.  Glad you like the paint job for Jayne's armour - was puzzling what to do and then when she said 'Sabine' I studied the reference and then went for it - gonna be an interesting masking job, I can tell you!)




Title: Re: Armour Planning & WIP for 2 of us
Post by: Hanjo Solba on May 17, 2016, 02:03 PM
This thread has great tips for newbies.  I am commenting so i can follow.  Keep up the great work!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on May 17, 2016, 04:10 PM
Yay to paint. Still is it really weathered enough?  :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on May 17, 2016, 08:34 PM
Just stop youre making us look bad. :p

Thats some top notch work. Cany wait to see any pieces you cast.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 18, 2016, 05:31 AM
Thank you all, once again.

Glad you're finding it useful, Lt. - I'm a newbie at this too, but I seem to have a knack of figuring things out so I'm hoping that by sharing the workarounds and things I've discovered as I build not only does it give more experienced folks me the opportunity to jump in and advise on better ways of doing things, but also hopefully saves other folks time, answers questions I had when I started and generally improves all our kits.

Right, well, things carry on apace this week and would be going even faster if coats of paint dried and cured quicker (although I admit I'm pushing it, leaving maybe 12 hours between coats rather than the 24 I should...)

Was puzzling how to get a smooth curve across the helmet ever since I drew the paint mockup the other month, then yesterday lunchtime, it occurred to me and I solved what I feared would be a real pain of a problem in a few minutes...

Stretch an elastic band across the helmet!!!
Easy to adjust and view from all angles - and a synch to then line masking tape right up to...
(http://i.imgur.com/5AWOnHi.jpg)
(http://i.imgur.com/yvnTaWv.jpg)

The result - perfect line across the helmet that looks like the 45-degree line I wanted at the front!
(http://i.imgur.com/FoKKTLD.jpg)

Lys'ias...(if that is your real name...Kyri!  ;))
Yes - it is looking pretty beaten up - I've been studying the level of battery that the screen-used Boba helmet looks like it's taken a massive hammering and I'm definitely trying to balance things so the underlying colours come through but don't distrupt the paint job - it's an interesting challenge.  What strikes me (and it's obvious really) is the way that this layered weathering 'grows' as you build up the layers.
As you can see above - I've laid down a new strip of red primer onto the dome and am intending on cutting back a few more areas to reign it in a little.

In other news -plates have now been hit all over with grey primer (since the helmet colour grey, Kobra's 'Winchester' is a bit too close to the colour of the flight suit and primer grey is lighter) and this morning I hit them with a spray of clear coat so that I should end up with a satin/gloss grey that won't latch onto any weathering washes like a true matt primer would.  Now the waiting begins - to let that cure for a day before I can start scrubbing off all the masking and salt...

Laters!
Title: Re: Armour Planning & WIP for 2 of us
Post by: TVarius on May 18, 2016, 12:50 PM
Looking more amazing! like she said above (my bad, thought it was someone else), stop making the rest of us look bad. I was fairly happy with my kit but now after seeing where yours has gone, I feel like my kit is now sub par.

TVarius
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on May 18, 2016, 10:36 PM
Looking more amazing! like he said above, stop making the rest of us look bad. I was fairly happy with my kit but now after seeing where yours has gone, I feel like my kit is now sub par.

TVarius
I know the feel vod. His gaunts are amazing.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 19, 2016, 04:06 AM
Dudes....this is really kind of you to say - especially from you OM guys who I know have been on here for much longer than I and by definition have completed kits.  If this carries on though, I think I'm going to need to build a bigger bucket!  ;)

Pleased to say that the grey primer and clear coat worked as I'd hoped - the clear coat gave me a nice glossy grey (really hard to get grey car paints that aren't metallic) which once I'd scrubbed all of the masking off ended up a nice satin finish - matching the same kind of sheen that the Kobra paints have given me on the helmet.

(http://i.imgur.com/EyeSVjl.jpg)

This is the same process as before - apply masking fluid with a Q-Tip, spray a few select areas with hairspray and sprinkle on rock salt...

(http://i.imgur.com/YPba131.jpg)

Interestingly the grey primer, on top of the red primer in a few select places gave me some orange peeling...

(http://i.imgur.com/xx1MGMc.jpg)

...which shows that even with cleanly scrubbed paint surfaces, with paints from the same manufacturer, and both primers at that, you still might get a bit of interaction.

Fortunately, it's pretty minimal so I'll either ignore it, rub it back with a bit of 2000 grit, or conceal it with the next coats of paint depending on where they're located.

Helmet-wise - I did what I said I was going to do - paint over some of the chipping to allow the cream/ivory a bit more coverage and to repair the grey bits on the 'T' that came away with the masking tape. 

Unlike the high pressure car primer paints I found that the Kobra paints, being low-pressure graffiti paints, allowed me to spray a small amount onto a bit of foil and then use a brush to paint them on, which speeded up things massively.

(http://i.imgur.com/mW5WxFK.jpg)

Today, with these few moments of downtime in my work I'll hopefully get a chance to throw on some masking and actually get to add some patterning and markings onto the plates.

Hope wherever you are on the planet, you're having a great day.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on May 19, 2016, 05:05 AM
like he said above,

I'm not a boy Vod'Ika.

Syko. When it comes to that orange peel. Its not so much the primers reacting to each other. Primer doesnt like to go over metallic paint. So it tends to crack and orange peel. I have the issie when I made a miniature of the door to the mines of moria. And I had the issue when repainting a pair of old gauntlets last year.

I think its something to do with the matallic giving off gass or possibly because its so slick and smooth the primer isnt gripping when wet and is shrinking or expanding slightly when drying. Causing the cracking or the orange peel.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 23, 2016, 06:00 AM
Thanks Kit!  (Damn you, Chemistry!)

Anyhow various family things meant I didn't get as much done as I'd hoped, but I still managed to finish the painting, masking and touch-ups (where the masking tape adhesive lifted all the paint right back to the silver, and highlighting all the edges with silver where they'd rubbed back to the black undercoat) to get the helmet and most of the plates to a point where all they should need are dirt washing and a final satin coat to seal them...

(http://i.imgur.com/OIT1zIv.jpg)

(http://i.imgur.com/9YJqnCl.jpg)

(http://i.imgur.com/NtpOPac.jpg)

(http://i.imgur.com/SGBhiKa.jpg)

(http://i.imgur.com/uvirA0w.jpg)

(http://i.imgur.com/KVRr6jS.jpg)


To do - left shoulder, backplate and kidney plate...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Mavik on May 23, 2016, 06:29 AM
Very nice, that is some great looking weathering.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kurshi BeJahaal on May 23, 2016, 06:25 PM
Dang. KILLER job with the weathering! It looks phenomenal!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on May 23, 2016, 06:44 PM
Much applause, vod.  I can't wait to see the full kit all put together!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on May 23, 2016, 08:11 PM
Dude your kit is looking amazing!! If i lived closer I'd be begging you to do my paint job!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on May 24, 2016, 03:11 AM
Dude your kit is looking amazing!! If i lived closer I'd be begging you to do my paint job!
I'd beg for a set of those gaunts myself lol but I'm across a rather large pond of sorts.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on May 24, 2016, 03:13 AM
I'd beg for a set of those gaunts myself lol but I'm across a rather large pond of sorts.
Same here! It's quite an exhausting swim. ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on May 24, 2016, 03:22 AM
Same here! It's quite an exhausting swim. ;D
Swim heh! My jet pack would fail ten minutes into the trip!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on May 24, 2016, 08:42 AM
Thanks Kit!  (Damn you, Chemistry!)

Anyhow various family things meant I didn't get as much done as I'd hoped, but I still managed to finish the painting, masking and touch-ups (where the masking tape adhesive lifted all the paint right back to the silver, and highlighting all the edges with silver where they'd rubbed back to the black undercoat) to get the helmet and most of the plates to a point where all they should need are dirt washing and a final satin coat to seal them...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4884_zpsoxcgoxmv.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4884_zpsoxcgoxmv.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4885_zpsgz5mjgey.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4885_zpsgz5mjgey.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4886_zps3jwce7wf.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4886_zps3jwce7wf.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4887_zpsow3iovrd.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4887_zpsow3iovrd.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4888_zpsfrypexuh.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4888_zpsfrypexuh.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4889_zpskpgu6g1i.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4889_zpskpgu6g1i.jpg.html)

To do - left shoulder, backplate and kidney plate...

Buy'ce looks beautiful...Eldar grav platform and all. lol I thought I noticed Wave serpent/falcon parts in your gaunts too....

Either way wonderful use of bits!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 28, 2016, 10:55 AM
Hey gang,
such lovely kind words from you all - darn this ocean between us - if someone over there has a spare Firespray-31 attack craft to make the journey, you're welcome to use the field near us for landing and we've got plenty of tea, beer and blue milk!

So, little bits and pieces done here and there over the past few days between finalling our game (http://dangerousgolf.com/) (released on 3rd June on PC, Xbox One and PS4 for a very reasonable price!  ;D), family and other stuff.

First up - taking a chunk out of an old sieve and installing it behind the keyslots using a combo of thick superglue + accelerator, 2-part epoxy and then, when it was all set, running over with hot glue to guarantee no rough edges...

(http://i.imgur.com/wrMILZF.jpg)

And, I fess up to stealing a few bits of Warhammer 40K from my son's old sets to use as greeblies (ironically we're only 6 miles away from Warhammer HQ in Nottingham, here in the UK) and the piece of Eldar (?) kit always bothered me as not quite looking Swarzy enough.  So, after thinking about it, and having recently replaced a pull-switch in my daughter's bathroom, I decided to use one of the parts to give that key slot a bit more of a 70's Swarzy touch...

(http://i.imgur.com/LzBjy0J.jpg)

I'm pleased to say that I finished off the backplate, kidney and left shoulder...

(http://i.imgur.com/tNfIHmt.jpg)

And came up with the following attachment method for the hand plates:

Strips of black elastic, the ends sewn and sealed with super glue, held in plate with small plates of flattened out PVC pipe and a small screw...

(http://i.imgur.com/zScqjR0.jpg)

The nice thing is, the texture on my gloves is so close to that of the elastic that unless I pointed it out to you, you wouldn't notice the strapping...

(http://i.imgur.com/RfYIVNw.jpg)

The result is really secure and allows my hands to flex really easily - had considered velcro or snaps but the elastic guarantees they're not going to drop off while allowing my hand to flex underneath them with no restriction.

And, finally, I attached the grenade rail on the left thigh (also known as various bits of plastic coat and trouser hanger parts and thick wire)...

(http://i.imgur.com/DDiLHLt.jpg)

So now, my kitchen table looks like this...

(http://i.imgur.com/Dcsbuqs.jpg)

All parts painted and distressed.  It's a nice afternoon here in Nottingham, all my chores are done for the day, the coffee machine is on and I'm about to attack this lot with dirt washes!

App is getting closer and closer...

(In other news, am slowly primer/weathering Jayne's plates in the background - still need to grab time when we're both free to do fitting of plates to her flak vest.)



Oh, and before I go...

You guys have been saying such lovely things about my weathering techniques, I figure I'd just do a few close-up photos and outline the steps I've taken in case it helps/inspires...

Things I've used:


How I've approached it...


(http://i.imgur.com/iLpkdD0.jpg)

This is how I got this effect - see the edges of the silver to the red, then the red to the grey - both are done with masking fluid first, then hairspray+salt on top - this really breaks up the hard edge of the masking and makes this look much more natural...

(http://i.imgur.com/FLcQhzE.jpg)

The above patch of weathering was built up by blobbing on the masking fluid, then adding one good streak out from the centre, and then blobbing around the base of the streak so that it emerged nicely from the patch.

(http://i.imgur.com/WmTeUFY.jpg)

(http://i.imgur.com/LYPTpb1.jpg)

And finally - on all of the edges where the silver may have rubbed back to the very base coat/Sintra/Foamex - get a pot of silver acrylic paint and brush on the highlights to bring those hard metal edges back again

It really isn't that difficult a technique - the trick is trying to get that 'guided but random' approach to everything - apply the masking in all the logical places, apply it a dabby/random fashion and thinking of the big picture and assymetry when it comes to laying it all out.

Perhaps that's all the help I can give from here.  If we have any Vok'Chi who can get to the Nottingham area and want to hook up and I can help/show how to do this drop me a PM.  Or, maybe I could pull together a video tutorial some time if that would be of use.

Anyhow, there's fresh coffee, an afternoon with a bunch of acrylic paint and some armour waiting for me.

Have a great holiday weekend, folks, speak soon!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on May 28, 2016, 12:15 PM
Awesome progress vod! Love the tutorial! Could you post a pic of the silver acrylic you use?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 28, 2016, 12:45 PM
Thanks
Silver acrylic I'm using for touch ups is Tamiya Chrome Silver X11
Spray is Valspar Chrome which I then clear coat with Hycote Clear Lacquer and then over that I rub on Rub n Buff silver leaf
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on May 28, 2016, 02:48 PM
looks absolutely fantastic mate.
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on May 29, 2016, 10:07 AM
loving the paintwork ...weathering is truly awesome
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 31, 2016, 11:06 AM
Thanks!

Well, had a busy weekend adding dirt washes and a satin lacquer coat to EVERYTHING, adding some padding under the shoulders of the flak jacket and bringing it all together, as well as wiring up some switches and LEDs.

Here's the helmet in its final form, with the protective film taken off the visor...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4940_zpsm1okbogg.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4940_zpsm1okbogg.jpg.html)

Here's how the thigh and grenades turned out when assembled...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4946_zpsdlxi9mb6.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4946_zpsdlxi9mb6.jpg.html)

And here's the gauntlets finally assembled with dirt wash and satin lacquer...

(Ended up using silver-painted tooth picks for the darts, used hot glue to create the diffusing lenses on the lights - works pretty well in the absence of having the perfect coloured plastic domes and lenses that I would have otherwise wanted to use...)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4933_zpsg6qsrr0x.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4933_zpsg6qsrr0x.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4928_zpslvhjrqzw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4928_zpslvhjrqzw.jpg.html)

Pleased to say that all of the holes and channels I'd drilled in the gaunts months ago paid off and made putting in switches and the like pretty easy.

Biggest mod was cutting a little more into the roof of the right gaunt to accomodate all 3 coin cells...
(http://i725.photobucket.com/albums/ww258/simorph/IMG_4937_zps49ihqk2h.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4937_zps49ihqk2h.jpg.html)

Decided to use coin cells to keep down the weight, and to simplify all the circuits, simply wired up one cell to each LED and dropped in switches as necessary.

Left gaunt was much less of a problem...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4931_zpswqlqwhnd.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4931_zpswqlqwhnd.jpg.html)

Pew! Pew!

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4930_zpsom1bfovw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4930_zpsom1bfovw.jpg.html)

Used a tip that I picked up from the YouTube channel  (https://www.youtube.com/watch?v=BS9jTi_PM-k)of using hot glue on soldered joints to insulate them from the rest of the wiring - really handy tip, that!


So I think I'm almost there...

So we did a pre-app photoshoot...


(http://i725.photobucket.com/albums/ww258/simorph/Helmet%20Off_zpsuh5i9drt.jpg) (http://s725.photobucket.com/user/simorph/media/Helmet%20Off_zpsuh5i9drt.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Front_zpsxosf8obx.jpg) (http://s725.photobucket.com/user/simorph/media/Front_zpsxosf8obx.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Right_zpsobiud7rk.jpg) (http://s725.photobucket.com/user/simorph/media/Right_zpsobiud7rk.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Left_zps3zcuzzx5.jpg) (http://s725.photobucket.com/user/simorph/media/Left_zps3zcuzzx5.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Back_zpsjnxzkihv.jpg) (http://s725.photobucket.com/user/simorph/media/Back_zpsjnxzkihv.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Carbine_zps26yfklcn.jpg) (http://s725.photobucket.com/user/simorph/media/Carbine_zps26yfklcn.jpg.html)


What have I missed?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on May 31, 2016, 04:12 PM
Looking great vod, really impressive. Nothing to add that wasnt mentioned in the other thread. Good luck with the last few steps  ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on May 31, 2016, 04:23 PM
Great work vod! Only thing that I see right off is the right thigh,  left side of the front view picture, is just a little low. And the right chest plate, also on the left side of the front view picture,  looks slightly twisted upward. But, both of those should be very simple fixes! :) As I've stated before, I love this kit vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on May 31, 2016, 04:27 PM
You sir, are a wizard.  It's been an honor to watch your build from the early stages to where you are now.  Everything you've done is top notch (except for that blaster...it just won't do, please box it up immediately and send it across the pond).  I think Vok'Chi is going to have a new OM soon.  ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on May 31, 2016, 04:34 PM
Everything you've done is top notch (except for that blaster...it just won't do, please box it up immediately and send it across the pond).

Oy! Anything to be disposed of comes to me. Vok'Chi rule ;) :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on May 31, 2016, 04:39 PM
Oy! Anything to be disposed of comes to me. Vok'Chi rule ;) :P

(http://i.imgur.com/2BqmimUl.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 31, 2016, 05:31 PM
 :laugh:

Thank you guys.  Point taken about the blaster, Rae, I agree, not good enough - I wouldn't wish it on you.  I'll keep this one here as a reminder to try to do better...  ;)

Righto, so taking the feedback all in, I've spent the evening attacking the soft parts with acrylic paint.  Found that raw sienna seemed to work best (along with varying amounts of black, burnt umber, yellow ochre and some flesh tone) - browns stood out better against the flight suit than greys...

(https://i.imgur.com/0AjJYHI.jpg)

Lots of 'muck' on the bottoms of the legs, surrounding the knees, elbows, edges of the cuffs and a few other large marks in as assymetrical fashion as possible.

(https://i.imgur.com/h1LMLoE.jpg)

Checked the vest and plates, and then threw on lots of acrylics, rubbing them in on the seams that will be visible and selected gaps between the plates...

(https://i.imgur.com/7DJKwdu.jpg)

Will suit up again soon and post more pics!

Thanks all!

Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on May 31, 2016, 05:40 PM
Your shin armor is riding a bit high and probably be brought down so the flight suit doesn't flare out at the bottom on you. Other than that I'm jealous of what you've accomplished here Vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Jun 01, 2016, 08:47 AM
I see a set of shiny new kill stripes in your very near future!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 01, 2016, 12:41 PM
It's the last 1% that takes 50% of the time!  Thanks all.

Made weathering, plate adjustments, etc and went out just now and shot new pics...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_2622_zpskz7qd0bu.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_2622_zpskz7qd0bu.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_2626_zpsgzl5i4qq.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_2626_zpsgzl5i4qq.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_2634_zpsroxngfaw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_2634_zpsroxngfaw.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_2641_zpsips9pjen.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_2641_zpsips9pjen.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_2652_zpsxtzal8i1.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_2652_zpsxtzal8i1.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_2654_zps9nn06zpp.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_2654_zps9nn06zpp.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_2642_zpsgcz3drpi.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_2642_zpsgcz3drpi.jpg.html)

Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 01, 2016, 12:57 PM
Vod, your kit looks great to me! I'd say you're ready for app submitting! :) I envy the perfect "flaws" of your kit if you know what I mean! ;)  Beautiful job Voss!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Jun 01, 2016, 01:48 PM
phenomenal kit, you're gonna give everyone a run for their money with Rookie of the year if not others next May 4th awards
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 01, 2016, 03:43 PM
Thanks!
Not done yet - time to turn my attention to Jayne's kit so she can look baddass and cool for SWCE!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Jun 01, 2016, 04:12 PM
Thanks!
Not done yet - time to turn my attention to Jayne's kit so she can look baddass and cool for SWCE!

(http://i229.photobucket.com/albums/ee43/reapwind/Gif%20collection/tumblr_npwq9fRJmt1tuall8o1_500_zpsmrtewnvt.gif)

And then while waiting for clearance you can be finishing off Jayne's instead of nail biting  ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Jun 01, 2016, 04:30 PM
Truly awesome looking kit  :o and as if the standard was high enough already lol ...hard to believe this is your first kit .... cant wait to see how jayne's kit comes out as well
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jun 01, 2016, 07:05 PM
You're in regional pre-app. Not expecting any of the others guys to see much, but this way you know it's spot on ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hanjo Solba on Jun 02, 2016, 10:41 AM
I am not worthy!! I hope my kit ends up half as good looking as yours.  Absolutely amazing work.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 03, 2016, 03:06 PM
Thanks!

Well, the awesome Kris, says I've passed Regional Pre-App...

The App form is now submitted...

...and I'm off to mask up Jayne's helmet for its first coat of faux primer!

(My advice to de-stress the app process - build two kits!)  :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 03, 2016, 03:09 PM
Thanks!

Well, the awesome Kris, says I've passed Regional Pre-App...

The App form is now submitted...

...and I'm off to mask up Jayne's helmet for its first coat of faux primer!

Very nice vod! Good luck to you! :)

(My advice to de-stress the app process - build two kits!)  :D

I shall be doing this very thing! I'm actually making my first and second kit at the same time! lol
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jun 03, 2016, 03:32 PM
the awesome Kris

Oooooh, I've moved up from being crazy to awesome!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jun 03, 2016, 03:50 PM
Oooooh, I've moved up from being crazy to awesome!
How about Crazy-Awesome!?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kyri on Jun 03, 2016, 03:58 PM
How about Crazy-Awesome!?

How about Crazy-Crazy?

Best of luck with the app Syko, not that you need it  ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jun 03, 2016, 05:16 PM
How about Crazy-Crazy?

Best of luck with the app Syko, not that you need it  ;)
We aren't talking about me now are we! ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Jun 04, 2016, 09:45 AM
I think it's safe to say we're all crazy.   :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 07, 2016, 04:29 AM
So, while you guys have been rating your levels of insanity and my app has being processed, I've been chipping along with Jayne's kit, concentrating on all the parts that don't need fitting to the flak vest.

Boot plates, hand plates, biceps and cod...

(Lighter levels of wear here than my beaten up kit)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4959_zps1d0efp8f.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4959_zps1d0efp8f.jpg.html)

And I decided to build a couple of helmet stands to display the helmets and to protect the paint job around the helmet base (during the months up to the final paint job I noticed that the edges of the ear caps were getting their silver paint rubbed back to black from sitting flat on surfaces)

Basically, took a square of wood, cut it with my new Japanese saw (boy, those things are awesome!)  Countersunk screw in the centre of the base, piece of old wooden curtain pole and topped off with a plastic dome (filled with P38) from an IKEA LED tealight that I'd bought for parts in a sale about a year ago.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4961_zpsrfqqamgg.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4961_zpsrfqqamgg.jpg.html)

Several rounds of sanding, filling and priming, and boom...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4967_zpshz4o4raj.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4967_zpshz4o4raj.jpg.html)

Helmets look much more badass and I've had a fun woodworking project.

In other news, Jayne's helmet paint job is underway.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4962_zpstrpstd2m.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4962_zpstrpstd2m.jpg.html)

Green base has been applied and as I type I'm waiting for the purple top coat to dry off, hoping that the masses of masking fluid that I applied to it last night come off to reveal all the various green markings as neatly as I hope they will.
(Decided to do a green base, paint on the intricate details with masking fluid, then go over with purple as I didn't fancy trying to mask around all the intricate shapes...first time doing it this way, so let's keep our fingers crossed that this approach gets the results I'm hoping for...)

Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 09, 2016, 03:16 PM
As always, amazing work vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 09, 2016, 04:30 PM
Thanks!

Quick update..

Took off the masking, didn't turn out quite as clean I'd hoped, so had to get in there with a brush to tidy up the edges...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4978_zpsnzeegxcx.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4978_zpsnzeegxcx.jpg.html)

Contemplating adding a few ivory outlines to the design to make it 'pop' a little more.

Also, upgraded my knees - the webbing clips that I was using to secure the elastic were a bit too wide and were pinching my knees.

So, I needed something thinner but equally strong to drop in place.

Rummaged through the scraps bin and found some offcuts from the visors - it's polycarbonate so it's tough but easy to cut with knife/scissors, so cut four pieces out and installed them - now the plates are just as secure but aren't likely to rub my knees raw, and it's just as neat a job as it was previously!

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4976_zpswu1ppfpi.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4976_zpswu1ppfpi.jpg.html)

Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jun 09, 2016, 05:03 PM
Where's those kill stripes already!?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 10, 2016, 12:28 PM
Probably encased in Carbonite, or something - the rate we Vok'Chi are app'ing right now, I'm not in a rush...
...but if by about lunchtime on the first Friday of Celebration I can get OM, that'd be ace!

Ryi'nock asked me a question about whether it was possible to see the snaps behind the plates, so I took a shot of my vest hanging over the back of a chair...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4983_zps7gvsjioh.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4983_zps7gvsjioh.jpg.html)

And a closer shot

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4979_zpsnejfb37r.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4979_zpsnejfb37r.jpg.html)

And closer

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4980_zpspbhi93nw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4980_zpspbhi93nw.jpg.html)

And closerererer...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4981_zpsrxboiybh.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4981_zpsrxboiybh.jpg.html)

Basically - I placed the snaps far enough in from the edges of the plates so that the flak vest and soft parts would bunch up behind them, plus the plates are curved - so it's a non-issue.

And here's all the masking for the pinstriping for Jayne's helmet...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4984_zpsyc7m0tce.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4984_zpsyc7m0tce.jpg.html)

...ready for spraying with the ivory paint...fingers-crossed...


Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 12, 2016, 11:04 AM
(I'm not considering this double-posting as it's a new update for a new day)

Spending the afternoon working on Jayne's armour fitting.

First up - making sure everything works from the waist downwards.

Have used a webbing belt to hang the cod from with snaps, with additional 'Boba Pouches' on it from either side.

Question for those familiar with CRLs for the ladies....does this look approvable?

(Knee strapping is black elastic, everything else is webbing or pleather)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5001_zpsptkpsb1o.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5001_zpsptkpsb1o.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4998_zps0exbd9dg.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4998_zps0exbd9dg.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_4996_zpsizcp6ufs.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_4996_zpsizcp6ufs.jpg.html)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 12, 2016, 11:07 AM
Vod your work is nothing short of perfection!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Jun 12, 2016, 11:16 AM
Everything looks solid to me. A bit of soft part weathering as always and maybe form the boot plates to sit on more securely as they seem to be slipping inwards. What's best to keep in mind is that the CRLs are the same for females and males, so just make sure everything is in compliance and looks good.

Got to say as always this looks amazing. your build quality and attention to detail is like that of some of our most experienced members. I see a lot of good coming from your neck of the woods. well more good :P.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 12, 2016, 03:25 PM
Thanks!

(Oh, and as you can see, the pinstriping masking on the helmet came out okay!)

Righto - what's wrong with this picture?

I'm seeing chest plate on the left of the image (Jayne's right) needs rotating counter-clockwise by a few degrees just to even up spacing to left of chest diamond/close the gap between the bottom of the 'fang' and the ab plate...

...anything else?

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5015_zpsanwojaou.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5015_zpsanwojaou.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5013_zps8re4sjdo.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5013_zps8re4sjdo.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5012_zpswsui74s2.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5012_zpswsui74s2.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5008_zpsgng7pure.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5008_zpsgng7pure.jpg.html)

If we can get this spacing/placement nailed, I'm cleared to paint up chest, back and pauldrons, then weather hard and soft parts and then pre-app...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jun 12, 2016, 03:31 PM
Apart from the tiny tweak on the front, the back plate looks to be pulling away from the back a fair bit at the bottom.

Other than that, looks good.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 12, 2016, 04:02 PM
Looks good vod! Only things I see, other than what's been said already, is the ab plate looks shifted down slightly on the left side of the picture, her right. Also, the bicep looks a little low on the left side of the picture, her right. :)

(http://i1175.photobucket.com/albums/r634/DenBarren/image_zps79tthpqf.jpeg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 12, 2016, 04:08 PM
Thanks folks - all easy fixes!  Bend a bit of backplate, move a couple of screws/snaps and push up an armband...

Let the final paint job commence!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 12, 2016, 08:13 PM
Congrats on getting OM vod! Well done!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Jun 13, 2016, 06:57 AM
It'll probably disappear with paint but the darting on the back looks a little pointy. (I'm being incredibly nit picky here) I'd maybe suggest smoothing it a tiny touch more before giving it another bit of paint, if you bend the plate more at the top of the shoulders it should fix the back floating problem, If you're going to try and smooth the darts a bit more (I highly doubt you'll NEED to, but just in case you want to) i suggest you reshape the back a bit more first just in case the change in shape makes the pointy darts better or worse.

I agree with what you've said about the right chest and what den said about the ab plate.

I feel like her vest might be a tough too baggy to pull away from her body like that with the back plate. but then again it might not be.

Looks great vod I look forward to seeing it done.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 13, 2016, 05:46 PM
Thanks everyone.

So...one fresh-faced space cadet reporting for duty!

All of these are attached with snaps, so the good thing is, if we get it right now, it's right forever...

Tweaked the positioning of the left (Jayne's right) chest plate by rotating counter-clockwise. rotated the right (Jayne's left) chest plate clockwise around the lowest fang and then tweaked the chest diamond to even out the spacing.  Double-checked the ab plate - that's 9.5cm up from the bottom of the vest all the way along.  (Oh, and for this pic, made sure the biceps were even!  :P)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5024_zpsvrnmbxy1.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5024_zpsvrnmbxy1.jpg.html)

Regarding the back plate...applied heat and bent it in from the point just under Jayne's shoulderblades (couldn't go any higher - the plate's resting right on her back)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5029_zpskkl4hvbl.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5029_zpskkl4hvbl.jpg.html)

Going to attack the points where the darts meet, but will have to do that by sanding down carefully.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5032_zpss0ndnljo.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5032_zpss0ndnljo.jpg.html)

If that chest spacing works for you guys I'll crack on with the paint job for shoulders and all of the front plates.



Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jun 13, 2016, 06:24 PM
Ab is a bit off center compared to the fangs and the diamond. Other than that you're kicking out a fantastic pair of kits!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jun 13, 2016, 06:59 PM
Much better on all accounts and the backplate as you said just needs the points rounding off a little.

If you're being perfectionist, what Dha said - your abs just a little skewed to the right on the picture.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 15, 2016, 11:03 AM
Quick update...

Attacked the backplate 'points' with a rasp, smoothed out the sharp edges created by bending the middle back down, and filled and sanded...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5033_zpsnxyte6yn.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5033_zpsnxyte6yn.jpg.html)

Back of hand plates attached with snaps (elastic straps weren't fitting comfortably)
Made the ab tweak on the vest (about 2mm sideways) then began paint job with faux red primer...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5040_zpsg31st835.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5040_zpsg31st835.jpg.html)

Next - add masking to the plates and spray the base paint colours...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 15, 2016, 05:07 PM
Nice, vod.  Looking forward to seeing Jayne with her kill stripes, too.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 19, 2016, 12:36 PM
Thanks Brett!

...and on the subject of stripes...here's the paint job in-progress on Jayne's plates from earlier this week.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5045_zpsv6c577xc.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5045_zpsv6c577xc.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5051_zpstlb0xyjn.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5051_zpstlb0xyjn.jpg.html)

Yesterday, I went over to Saz's Fortress to attend my first Armour Party and although I couldn't stay long, spent a great few hours meeting some of our lovely members of the Vok'Chi.

In addition to sampling Saz's legendary bacon sandwiches, I was able to compare helmet sizes with Vardamir (we both have buckets that are on the large size - I think that's how we roll in Derbyshire) and help Ryi'nock weather the crap out of his flightsuit.

Here's Ryi'nock (Raoul) banished to the spot under the tree slathering his flight suit with loads of different acrylics...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5047_zpszm6ocbx6.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5047_zpszm6ocbx6.jpg.html)

And from left-to-right:

Niabi (Ken), Saz (Rich), Vardamir (Paul), Nala (Katie) and Reyn (Paul) - suffice to say, the air was thick with PVC dust and the smell of car body filler...as well as double entendres about Saz polishing Mandalore's helmet (and impressive it is too!)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5048_zpswcgwydxj.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5048_zpswcgwydxj.jpg.html)

And here's the helmets line up...the in-progress new Mandalore helmet on the left there...then Saz, Vardamir, me, Reyn and Ryi'Nock...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5049_zpso8zcuhgn.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5049_zpso8zcuhgn.jpg.html)

Anyways, sad to say I had to leave early in the afternoon for other commitments but it was lovely meeting everyone in person and only makes me more excited about Celebration and the prospect of doing a bit of trooping with everyone.

And, now to today and (dodging outside to avoid the rain showers) Jayne's first full kit test:

(http://i725.photobucket.com/albums/ww258/simorph/IMG_3054_zpsjmfhlnox.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3054_zpsjmfhlnox.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_3057_zpsijquada3.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3057_zpsijquada3.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_3060_zps1jndmtbw.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3060_zps1jndmtbw.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_3063_zps8hl4fyss.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3063_zps8hl4fyss.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_3080_zpsjohqhqpj.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3080_zpsjohqhqpj.jpg.html)

And remember those hidden neodymium magnets in the sides of the ear caps...?

Well, Jayne (huge Disney fan)'s only real stipulation was the ability have a helmet with mouse ears... (for 100% unofficial trooping of course - hence the totally invisible attachment method!)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_3075_zpsldh5xbzn.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3075_zpsldh5xbzn.jpg.html)

So - remaining to do on Jayne's kit:

1. Dirt wash all plates + spray with clear coat
2. Electronics in gauntlets
3. Additional pleather piece on girth belt to conceal velcro that's exposed on the middle back

Fingers-crossed I can do that this week so we can start pre-app next weekend.

Anyone see anything we can't (all spacing adjustments were done as per feedback in other posts last week)?

Thanks all!




Title: Re: Armour Planning & WIP for 2 of us
Post by: Ryi'nock on Jun 19, 2016, 12:55 PM
Amazing work Syko!
Thanks for your help again ;)
Looking forward to trooping with you both at CEL!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kryamla Redalur on Jun 19, 2016, 01:11 PM
Wow I love the paint scheme on those plates! Looks amazing! Great work :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 19, 2016, 01:18 PM
Amazing work as always vod! Looked like the armor party was fun!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jun 19, 2016, 01:26 PM
Nothing I can see beyond what you've mentioned. And watch out, you may end up with a commission for more ears like that when somebody in the clan *coughNalacough* sees that :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 19, 2016, 01:32 PM
Thanks Kris, much appreciated.
I must confess to giving Nala a sneak peek at the AP yesterday.
Perhaps after CEL we could look into setting up a CRL for a Mous'alor Brigade? ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Echo Darklighter on Jun 20, 2016, 02:14 AM
Impressive kit, vod.  Good stuff!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jun 20, 2016, 08:41 AM
Much talent you possess Ner vod! Love the ears!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hanjo Solba on Jun 20, 2016, 04:11 PM
I really wish I had this level of skill.  Great job on both kits! 
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 20, 2016, 06:56 PM
Stellar work, as always!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 21, 2016, 04:35 PM
Thanks again everyone!

Don't be so down on yourself, Lt! you'll get there - I seem to have a knack for this kind of thing but I'm here if you've got questions, just ping me and I'll do my best to explain how I managed to do something.

Righto - so we're hurtling towards those app photos for Jayne...here's the state of all those plates after the thorough black wash, dirt wash and a few splashes of espresso that they've had these past three days...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5053_zps1oncpni9.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5053_zps1oncpni9.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5054_zps88kqgzpa.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5054_zps88kqgzpa.jpg.html)

I blackwashed thoroughly, left that overnight and then went in with burnt sienna, burnt umber and hit a few spots on the plates aiming for asymmetry all the time

Then I flicked on a couple of splashes of espresso since that has such great colours and dries with the appearance of a thin motor oil
(http://i725.photobucket.com/albums/ww258/simorph/IMG_5056_zpswyq0k7rq.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5056_zpswyq0k7rq.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5060_zpsh0ymntyp.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5060_zpsh0ymntyp.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5058_zpsokv2lrtj.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5058_zpsokv2lrtj.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5057_zpsjemmmd9r.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5057_zpsjemmmd9r.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5059_zpsgey7seqy.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5059_zpsgey7seqy.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5061_zpsgfblrr8n.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5061_zpsgfblrr8n.jpg.html)

Boots have been hit with bits of acrylic too - means that they're clean but only look dirty

Gauntlets are a little further on, having been hit with satin clear coat - only need to wire up the electronics in these now...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5069_zpsk4ne1lut.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5069_zpsk4ne1lut.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_5066_zpsl17ce6pq.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_5066_zpsl17ce6pq.jpg.html)


So that's all soft parts dirtied up, all plates and helmet washed and gauntlets done bar the electronics. 

I think we're on for pre-app pics this weekend (or maybe sooner if we have an evening free and it isn't too dark)

Righto, I'm off to spray all the plates with clear coat...see you lovely folks in a few days with another update...

And once again, thanks for the kind comments and encouragement.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Jun 21, 2016, 08:45 PM
Continuing to be impressed by your work brother. Your craftsmanship makes me jealous!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 25, 2016, 12:02 PM
Thanks!

Okay, so here we are...everything's weathered, clear coated, adjusted, tweaked and refined...Here's Jayne's pre-app pics...

(http://i725.photobucket.com/albums/ww258/simorph/Front_zpsobvhawnn.jpg) (http://s725.photobucket.com/user/simorph/media/Front_zpsobvhawnn.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Right%20side_zpsegxa62ef.jpg) (http://s725.photobucket.com/user/simorph/media/Right%20side_zpsegxa62ef.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Back_zpsh8piy1bq.jpg) (http://s725.photobucket.com/user/simorph/media/Back_zpsh8piy1bq.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Left%20side_zpstuznkgzk.jpg) (http://s725.photobucket.com/user/simorph/media/Left%20side_zpstuznkgzk.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/Helmet%20off_zpswfcmr7l3.jpg) (http://s725.photobucket.com/user/simorph/media/Helmet%20off_zpswfcmr7l3.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_3879_zps8fdn1dmk.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3879_zps8fdn1dmk.jpg.html)

Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Jun 25, 2016, 12:12 PM
looking awesome, good luck jayne.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 25, 2016, 04:34 PM
Thanks from both of us, Jett.

Well, I started this crazy project a year ago with the intention of just making a couple of costumes for Celebration Europe.
Pleased to say that that objective was met!

What I didn't expect was to meet all you lovely folks and have such a great time here on the boards.  Everyone's been so supportive and encouraging.  I hope sharing my journey and ways I've found of working around things has been helpful, and I'm looking forward to meeting more of you in the future, starting at Celebration and hopefully many troops after that.

And to top it all, the mighty Kris has given us the thumbs-up - App is now submitted...  Fingers-crossed that'll be us both as OMs for Celebration!

Yay!
 ;D

Hope everyone's having a great weekend.  Thanks once again, guys!
Title: Re: Armour Planning & WIP for 2 of us
Post by: dee on Jun 25, 2016, 05:45 PM
good luck , i'll cross my finger's too every little helps


*crosses finger's*

Dee
Title: Re: Armour Planning & WIP for 2 of us
Post by: DAK Beroya on Jun 26, 2016, 08:58 AM
got to say thats 2 good looking kits
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Jun 27, 2016, 04:24 AM
looks amazing to me. fantastic work.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kryamla Redalur on Jun 27, 2016, 01:29 PM
Awesome job! Good luck to you both!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Jun 27, 2016, 06:05 PM
Such clean, beautiful work! Both of you!
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Jun 28, 2016, 04:17 PM
congrats on your OM ...jaynes kit looks great as well ....good luck
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jun 28, 2016, 05:05 PM
One year for a quality pair of kits! Congrats Vod you earned it!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Nikjay Voss on Jun 30, 2016, 05:58 PM
And thanks to all Simes hard work (I can take no credit apart from support and coffee making) I have just received my email to say my application has been approved and I am now an official member - woo hoo!!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jun 30, 2016, 06:03 PM
And thanks to all Simes hard work (I can take no credit apart from support and coffee making) I have just received my email to say my application has been approved and I am now an official member - woo hoo!!!

Congratulations Vod! Your kit looks awesome! Only regret is that there won't be anymore project updates! I have thoroughly enjoyed watching the progress!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jun 30, 2016, 06:22 PM
Congratulations Vod! Your kit looks awesome! Only regret is that there won't be anymore project updates! I have thoroughly enjoyed watching the progress!
It's called Upgrades Vod. Much to be done with upgrades!
Congratulations to the Both of you for high quality kits and the new Official Member status! Now pretty please do trading cards as I need a pair! ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jun 30, 2016, 11:00 PM
Congratulations!  That's so awesome!  Your kill stripes are going to look great - as soon as the tech team is able to add them.  :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 06, 2016, 12:57 PM
Pleased to say that finally the stripes arrived on the profile, and that Jayne is now OM #1492!

So, a little update after a lot of sewing recently...

Discovered that I had problems with the gun sling stlipping off my shoulder - so added a pleather strip to the inside to hopefully give a bit more grip to my flak jacket...

(http://i725.photobucket.com/albums/ww258/simorph/Photoshoptest640_zpshmeyyddr.jpg) (http://s725.photobucket.com/user/simorph/media/Photoshoptest640_zpshmeyyddr.jpg.html)

Sewed some his-and-hers matching helmet padding - attaches with Velcro to the inside of the helmets...and is detachable...and therefore washable...

(http://i725.photobucket.com/albums/ww258/simorph/Photoshoptest640_3_zps8nkdrrza.jpg) (http://s725.photobucket.com/user/simorph/media/Photoshoptest640_3_zps8nkdrrza.jpg.html)

Added some detachable pads to the insides of my gauntlets - attached with a single snap in the middle - just to bulk out the back end of the gaunts as the right one has a tendency to slip and twist a little...

(http://i725.photobucket.com/albums/ww258/simorph/Photoshoptest640_2_zpsfuzltwtp.jpg) (http://s725.photobucket.com/user/simorph/media/Photoshoptest640_2_zpsfuzltwtp.jpg.html)

And then, pouches...

By pure chance, my Mum had bought an Aker Amp in an attempt to help with some hearing difficulties but found it impractical.  When she asked if it was any use to me, I jumped at it.

Custom pouch for my girth belt!

(http://i725.photobucket.com/albums/ww258/simorph/Photoshoptest640_1_zpsdczougis.jpg) (http://s725.photobucket.com/user/simorph/media/Photoshoptest640_1_zpsdczougis.jpg.html)

And, planning ahead for Celebration, the topic of carrying around our stuff came up - we don't have pockets in the kits (of course!) so needed to come up with a solution that would not only look in-world but be secure.

So I bought some really cheap leather neck wallets from Amazon at £2 each and sewed two into Jayne's pouches, and made a third, horizontal pouch for me (pic above)

(http://i725.photobucket.com/albums/ww258/simorph/Photoshoptest640_4_zps7rjxklhq.jpg) (http://s725.photobucket.com/user/simorph/media/Photoshoptest640_4_zps7rjxklhq.jpg.html)

The great thing about the neck wallets is that they are designed to carry phones, cash, id, etc and have some nice zips to keep everything safe, any they're the perfect size to hide within the pouches, and being dirt-cheap I had no qualms about sewing them into our gear so they won't fall out.

Current things on the checklist to be done next:

...and a whole lot more stuff including building a sidearm to fit my holster and a breaching charge so I can apply for Urban Assault

It never ends!  (And that's brilliant!)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 07, 2016, 01:52 PM
A follow-up post for another day (so I'm not double-posting!) :)

Ages ago I bought a sheet of waterslide decal paper that I thought might come in handy for creating decals for our kits.  Now that we're OM's I decided to give it a try and see whether it would work for us, and whether it would be any good for putting the clan markings on our shoulders.

So, I broke out Illustrator and did a couple of vector versions of the clan logo, sized for our respective shoulders, did a couple of colour variations to see what would work when the paper was used as a decal.

(The paper's great - print onto it with your printer, let the ink dry for 30 minutes, then 3 coats of clear coate 15 minutes apart, leave over night = page of customised waterslide decals...)

(http://i725.photobucket.com/albums/ww258/simorph/Untitled-1_zpsri1wkuvn.jpg) (http://s725.photobucket.com/user/simorph/media/Untitled-1_zpsri1wkuvn.jpg.html)

Anyways, rapidly discovered that the clan logos weren't going to work for us as the underlying transparency means the colours don't hold up against a dark background (you can get paper where the white stays white on the decal, but this paper the decal is transparent and relies upon the ink for all its colour)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0067_zpspmoc9axr.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0067_zpspmoc9axr.jpg.html)

But, where the paper really shone was in small decals - Mandalorian letters and numbers that represent our OM # and our characters' first names...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0068_zpsaehvyrcc.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0068_zpsaehvyrcc.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0069_zpsyahurpqu.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0069_zpsyahurpqu.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0070_zpscpiatgvj.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0070_zpscpiatgvj.jpg.html)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0072_zpsy7mzwyjm.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0072_zpsy7mzwyjm.jpg.html)

I'll weather these in with a few intentional scratches, a bit of dirt wash and a clearcoat.

As for the clan logos, I'll do them now 'the old fashioned way' with a stencil and spray paint, but this was a worthwhile exercise since the paper only cost a few pence and it's definitely a good way of getting nice clean lettering and symbols.

Right, back to sewing tonight - to finish off the custom helmet bags or else we'll be wearing our buckets in the car to Celebration...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jul 07, 2016, 03:19 PM
Love those decals Vod.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jul 07, 2016, 05:29 PM
I actually really like the faded out look from the clan logo you've got there. Not what you were after for that, but definitely a nice effect when used where you want that sort of look.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 11, 2016, 12:41 PM
Yep - can really recommend the decal paper - here's what I bought: https://www.amazon.co.uk/gp/product/B006DDK0OY (https://www.amazon.co.uk/gp/product/B006DDK0OY) 1 sheet for £1.45

One thing I didn't use it for but should have would be decals on my gauntlet keypad...only occurred to me once I'd printed the whole sheet out and cut it into bits!
But definitely the way to do lettering and complex, accurate details, things on the side of Rebel Pilot helmets, etc.

The approach I eventually took was this one...

Masking tape on the plates, then glued print outs on top with some contact glue...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0073_zpsrxgwk1jy.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0073_zpsrxgwk1jy.jpg.html)

FRESH knife blade to cut the whole thing out...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0076_zpsk1wzfegv.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0076_zpsk1wzfegv.jpg.html)

Spray, remove tape, curse at the layers of paint the masking tape lifted...

(I'm beginning to think this may be a side-effect of the salt weathering - despite getting a good scrubbing with soap and water, the hairspray used to fix the salt is creating a thin barrier between the coloured paints and the silver which weakens the grip on the top coats.  Add masking tape and it lifts the top coats in a few random, but annoying places.)

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0078_zpsktwaxunr.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0078_zpsktwaxunr.jpg.html)

Touch up the missing bits of paint...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0079_zpsphocx1tc.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0079_zpsphocx1tc.jpg.html)

Dirt wash and clearcoat it...

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0082_zps6mqhfptb.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0082_zps6mqhfptb.jpg.html)

(Anyone on the App Team that has to deal with UMs wanting to put the clan sigil on before app, worrying about weathering, etc, feel free to point them to this post! ;) )

For the rest of the weekend, I broke out the soldering iron and made a couple of USB-powered fans for mounting in the helmets.

(http://i725.photobucket.com/albums/ww258/simorph/IMG_0085_zps63cffjpo.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0085_zps63cffjpo.jpg.html)

...and spent many hours working on tiny tweaks to our kits, practicing the whole dance routine of the two of us getting kitted up together at the same time as well as sewing both padding for our immense armour crate and a couple of helmet bags so we can get everything to Celebration in LESS THAN 4 DAYS!

Still have a list of minor 'To Dos' as long as my arm to be completed before Friday morning, but as long as I 'Stay on Target' I'm sure we'll be fine.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 12, 2016, 12:06 PM
...and the prep for Celebration continues...

Finally finished two custom helmet bags...

(http://i.imgur.com/TcJGNyn.jpg)

2m of material, some filler, a circle of card to give the base a little more resilience and repurposed the webbing from an old laptop bag strap.  Learned how to sew button holes on the bag for my helmet - to allow two of the antennae to poke out of the top of the lid!

(These took a lot longer than anticipated - the fabric is lightweight, water resistant but really tough, which meant lots of opportunities for the sewing machine to jam at the most inopportune times and a few meters of hand-sewing that I swear has improved my grip strength by 500%!)

More tiny details and tweaks to address tonight as the Countdown to Celebration continues!


ADDITIONAL UPDATE 13 July:

Added a grey Wookiee braid after this thread (http://mandalorianmercs.org/forum/index.php?topic=116966.0) popped up about us older members of the MMC...

(http://i.imgur.com/64dc2Gd.jpg)

And to stop my carbine sliding off my shoulder (despite the sling being attached in the same way as Boba's) I turned the sling into a 3-point one by adding an extra strap that goes from my right shoulder, across my chest to my left shoulder...

(http://i.imgur.com/rPKPTGa.jpg)

Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jul 13, 2016, 12:20 PM
Very nice vod! Love the wookie braid! I read the link, love the idea behind it! :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 14, 2016, 03:09 PM
Thanks Den - I understand it'll be a while before you join the Grey Brigade (http://mandalorianmercs.org/forum/index.php?topic=117581.0) ...yep, Zolar made it a thing!

Just sharing a link to Jayne's blogspot where she blogs her take on our first year becoming OMs...

(http://3.bp.blogspot.com/-2h1qz2BmD4U/UCfR2d8YUuI/AAAAAAAAAHE/TEiODm8VWNA/s80/JP2MK%2BProfile%2BPic.png)
http://jp2mk.blogspot.co.uk/2016/07/star-wars-celebration.html (http://jp2mk.blogspot.co.uk/2016/07/star-wars-celebration.html)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Jul 14, 2016, 04:22 PM
Thanks Den - I understand it'll be a while before you join the Grey Brigade (http://mandalorianmercs.org/forum/index.php?topic=117581.0) ...yep, Zolar made it a thing!

Just sharing a link to Jayne's blogspot where she blogs her take on our first year becoming OMs...

(http://3.bp.blogspot.com/-2h1qz2BmD4U/UCfR2d8YUuI/AAAAAAAAAHE/TEiODm8VWNA/s80/JP2MK%2BProfile%2BPic.png)
http://jp2mk.blogspot.co.uk/2016/07/star-wars-celebration.html (http://jp2mk.blogspot.co.uk/2016/07/star-wars-celebration.html)

I'm not sure what the age requirements are ,but I'm sure at least another 23 years if it starts at 40. 33 if it starts at 50. :) But I plan on still being an active member then.

I checked out the blog, it looks good vod! :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 14, 2016, 05:17 PM
Thanks! You'll see why I had to give Jayne the option of mouse ears now! ;)

Last minute running around doing stuff on the computer...

Finally got the iPod slideshow set up and working in my chest plate...

(http://i.imgur.com/VyHcxDg.jpg)

Added a couple of elastic straps to guarantee it doesn't slip out during trooping...

(http://i.imgur.com/DJuxnMf.jpg)

Created slideshows for our gauntlets digital photo frames...

(http://i.imgur.com/BJsAD9Y.jpg)

(http://i.imgur.com/w2Gb71M.jpg)

Here are the 128x128 pixel images I cooked together for it mashing up bits of Google imagery.


(http://i.imgur.com/oPl4Bow.jpg)(http://i.imgur.com/DWSYSkt.jpg)(http://i.imgur.com/iwx7Fv9.jpg)
(http://i.imgur.com/C0i1jTR.jpg)(http://i.imgur.com/mwQ9LcX.jpg)(http://i.imgur.com/ezxwFbQ.jpg)
(http://i.imgur.com/5nurL3J.jpg)(http://i.imgur.com/npwaTPF.jpg)(http://i.imgur.com/x4LOlgF.jpg)
(http://i.imgur.com/NRta2WP.jpg)(http://i.imgur.com/DWjgmj9.jpg)(http://i.imgur.com/05v7FVx.jpg)

(I had to include a Lothcat in there at the end, sorry...)

Right - it's 22:15 here in the UK.  Time to start packing for the big drive to London tomorrow and the culmination of the journey I began over a year ago - two Mandalorian costumes to go cosplaying at our first convention together....wow, what a ride it's been so far!


Title: Re: Armour Planning & WIP for 2 of us
Post by: Ragnar Jast on Jul 14, 2016, 05:32 PM
Wow!! Both those kits are extremely awesome!!! Congrats on your OM
A follow-up post for another day (so I'm not double-posting!) :)
So if you wait a day you post rather than just edit your other post? I ask cause my WIP sank to page two and I'm adding stuff but people probably won't see it :( Have fun at celebration!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 14, 2016, 06:41 PM
Thanks.

With the double posting thing - I've always taken it in the spirit that I believe it's meant in - don't post multiple times during a day and spam the feeds, but sometimes if no comments have been added and a few days have gone by then it's okay - especially if you're posting a sufficiently different update to what you posted before.

I could be wrong, but that's the way I've approached it and I haven't managed to tick anyone off yet! ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: capnsmirk on Jul 14, 2016, 07:29 PM
Mate. It's like you got OM and went mental with your build! the detailing is excellent, well done!!

Love the loth cat btw! made me chuckle haha
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jul 14, 2016, 08:41 PM
Mate. It's like you got OM and went mental with your build! the detailing is excellent, well done!!

Love the loth cat btw! made me chuckle haha
That's the way it's supposed to go Vod.
Title: Re: Armour Planning & WIP for 2 of us
Post by: capnsmirk on Jul 14, 2016, 08:45 PM
That's the way it's supposed to go Vod.


Oh. Yeah! *facpalm* haha
Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on Jul 22, 2016, 05:23 PM
Seriously.......seriously dying from the awesomeness.... :o :o :o
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 02, 2016, 06:12 PM
Well, I thought I'd better drop a line to let you know how it all went in the end.

Technical stuff first:


(http://i.imgur.com/3uzEhPh.jpg)

We had a terrific 3 days at Celebration and spent the majority of the time in kit.  Indeed, what with the prices on the stalls and the ridiculous queuing times for everything we quickly decided to sack off every aspect of Celebration and spent our time having fun with our Mercs Family - indeed, I think as a first con experience, Jayne and I wouldn't have stuck around for much longer than maybe a day-and-a-half if we hadn't decided to go in costume.

This was our first experience of any type of costuming/cosplay at all and boy, was it fun.  I've had a terrific time this past year constructing our gear and had not really been thinking much about what it would mean to wear it - I've heard Adam Savage talk about wearing the costume being the other 50% of the experience - damn straight.  On some days it took us a good 30 minutes to get to the booth.

(http://i.imgur.com/s0Ls8ta.jpg)
(photo credit: Niabi)

Highlights of the weekend were:

(Friday) in addition to meeting all members of our wonderful Mando Family, meeting loads of folks who I hadn't seen for years, who happened to be at Celebration and I ended up bumping into by chance.

(http://i.imgur.com/hLIZe5C.jpg)
(This believe it or not is my childhood friend who I went to see Star Wars with back in '78 and our head bridesmaid - we hadn't seen each other in 8 years until Celebration...where we promptly dumped her in a jail cell)

(Saturday) working on the booth for few hours, helping man the jail cell and being a training sergeant for the kids in the games area, attending the Mercs talk and with Jayne, Ryi'nock, Tracyn & others being able to show off our kits to a vast audience of folks who attended

(http://i.imgur.com/jB9v0zr.jpg)
(photo credit: Saz & Niabi)

(http://i.imgur.com/BSxfSNH.jpg)
(photo credit: Saz & Niabi)

(Sunday) helping out with the Family Area and meeting a whole bunch of Dads who, after chatting to them wanted to make their own kits...and I believe some of them have actually started on them here on the boards!

(http://i.imgur.com/ybbzsWE.jpg)

And joining in the group photo and the Honour March with everyone who attended in kit - standing amongst some 50 Mandos shouting 'Oya!' together - that's something, I tell you!

(http://i.imgur.com/diMGqN5.jpg)

(video credit: Slimsidious)

And finally, spending time with Tom (our Mandalore) and the rest of our Mando Family for a terrific meal - never felt more welcomed by so many folks I'd never met in person before.

...and to top it all, a total surprise - Dave Filoni (yes, THAT guy - that guy who could've been at any swanky London meal that night but chose to spend it with us) stopped by the Meal on the Sunday night to say hello to everyone - a really nice chap who had time to talk to everyone...and in fact got into a discussion with Jayne all about her mouse ears and whether or not they could be made canon...

(http://i.imgur.com/8Jp7KS3.jpg)

For more a in-depth report and more photos from Celebration, Jayne's been busy on her blog:

(https://3.bp.blogspot.com/-kqyh6r--N7I/V4_TyQceSnI/AAAAAAAACvY/Pe9HlT4-Py4Y08CXNtcdp5gr9gUwuS7egCKgB/s1600/JayneMiniMando.jpg)
http://jp2mk.blogspot.co.uk/2016/07/wow-what-weekend-day-1.html (http://jp2mk.blogspot.co.uk/2016/07/wow-what-weekend-day-1.html)
http://jp2mk.blogspot.co.uk/2016/08/wow-what-weekend-day-2.html (http://jp2mk.blogspot.co.uk/2016/08/wow-what-weekend-day-2.html)

Oh, and we made it onto the Star Wars Live! stream too:

https://youtu.be/1xfVtfdervc?t=17042 (https://youtu.be/1xfVtfdervc?t=17042)

(http://i.imgur.com/K0XCRI6.jpg)

A truly memorable weekend, an amazing experience and so many lovely people.

When I got back to the hotel on Sunday night I found that Adam Savage's Love Letter to Cosplay talk at TED had appeared in my feed - this dude not only knows how to build costumes, he manages to articulate what they mean too...I recommend sparing some time to watch this...




Oh, yeah...and then, like a week after Celebration, this happened...

(http://i.imgur.com/55hTMaN.jpg)

Um...wow.

Thanks everyone for sharing my journey these past 14 months - I've had such fun, made so many friends and I'm looking forward to helping as many folks as possible in this exciting new role.

Oya!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Aug 02, 2016, 07:27 PM
First,  congrats on the new rank vod!  8) And second, I so wish i could have been there! :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Aug 02, 2016, 08:33 PM
Congrats Vod.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Malek Dair on Aug 03, 2016, 08:48 AM
Huge congrats to you vod! Great photo essay as well!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Vyst Nel on Aug 03, 2016, 11:12 AM
Congratz, vod! I've been following this thread with great interest for some time now (and often reference it for my own build). To see it culminate in such a fantastic way is nothing short of inspiring.  My helmet off to you and your wife, sir.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 08, 2016, 06:38 PM
I've just made a little upgrade to our kits, adding the supporter emblem to show our support to the folks over at the QMU:

(http://i.imgur.com/JWzY2ue.jpg)

Our second troop is coming up at York at the end of the month so it's soon going to be a matter of getting our kit out and double-checking for fixes, mods and such.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kurshi BeJahaal on Aug 09, 2016, 08:45 PM
Congrats and we'll done! I'm glad to see that you've got stripes and a title! Your time has paid off! Incredible looking kits you two have.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kitala-Enby on Aug 11, 2016, 05:24 AM
I love your slow build up of meaningful sigils. Looks awesome vod.
Title: Re: Armour Planning & WIP for 2 of us
Post by: spideyplumhead on Aug 14, 2016, 06:04 AM
congrats on your new rank ... and loving all the new emblems, both kits look stunning and a constant source of ideas  ...gutted i missed you at celebration
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 24, 2016, 06:31 AM
Well, after far too long of being away from the forums (family illness and, ultimately a bereavement kept me away), I must say, it's good to be back.

We had fun trooping at our local Disney Store in Nottingham for the release of the Rogue One toyline...

(http://i.imgur.com/pEFIyma.jpg)

And earlier this week I finally had some time to make a small mod to our gauntlets that I've been wanting to do for quite some time.

Our original use of digital picture frames worked really well...for five minutes.  But sadly we found the frames timed out and switched themselves off.

So, having seen how long-lasting coin cells and LEDs are, I came up with the following solution that will mean our gauntlets will look more alive during troops and add more illumination for photographing.

I built two custom circuits - the one on the right being a flashing red LED and a constant white LED wired in parallel with a switch and a coin cell holder.

The second, I took an IKEA LED tea light, cut it down and soldered a flashing red LED on top of the existing white LED so I ended up with the same kind of circuit.

(The reason for doing this was a matter of what spare parts I had and I found that the IKEA tea light was just the perfect size to fit in Jayne's gaunt.)

(http://i.imgur.com/S3VL9rX.jpg)

(http://i.imgur.com/ySpsnH8.jpg)

I glued some 'screen glass' - made out of clear bottle plastic heated for a couple of seconds with a heat gun and flattened and printed out a couple of images onto decal paper that I then applied to the inside of the 'glass' (if you're doing this - this will mean your image becomes flipped!)

(http://i.imgur.com/kTJfq4k.jpg)

Then, with that dry, I took some wax paper and glued and sealed it onto the decal using PVA glue - this diffuses the light - without it you can see straight through into the circuits and LEDs...

(http://i.imgur.com/wUuiKhg.jpg)

(http://i.imgur.com/g1MqqUH.jpg)

And while I'd love a super sharp always animating digital display, this little option displays brighter, more animated and longer lasting than the previous attempt.

(By having the white LED it means that the 'display' always has some illumination and the flashing red LED adds animation, with the red decal meaning that everything ends up differing shades of red.)

Happy Holidays folks, it's great to be back.

Just started building a sidearm for my empty thigh holster.  I'll post pics as I progress.


 
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Dec 24, 2016, 11:33 AM
Congrats on your promotion, vod, and as always, great work on your kit.  I'm hoping one day we'll be able to troop together somewhere.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ohl'd Vart on Dec 24, 2016, 11:42 AM
Good to see you back!  :D

Rob
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Dec 24, 2016, 11:49 AM
Good to see you back in action! Great work as always vod!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 02, 2017, 12:45 PM
Thanks guys
well, part of this holiday's highlights has been having the time to cut and hack at pieces of wood.  So here's how things have gone so far...

I made a rough cardboard template to work out the rough shape for my hold-out blaster...

(http://i.imgur.com/uTreN9F.jpg)

And then banged that onto the scanner and using Illustrator worked out a paper template (I could have used pencil and paper to trace but I've got access to the tools and can guarantee a right-angle in Illustrator will be more accurate than one I draw with a set square.)

(http://i.imgur.com/t1HofgK.jpg)

After that, it was cutting out three layers of MDF - giving the middle one a nice big tab and slot to allow the barrel to be fitted onto and slid back into place...

(http://i.imgur.com/yfYx5As.jpg)

(This was quite a job as although the blaster is made of three layers of MDF I used six separate pieces of MDF to make them - I was cobbling it together from various offcuts I had laying around!)

Shaping of the grip was done with a rasp, Dremel and sandpaper, cutting the parallel slots in the front of the body of the gun was done with a box cutter, a metal ruler and a file (I'd originally intended to Dremel it but when I cut a guideline with the box cutter I realised I could get better results with more control with a straight edge and a knife.)

(http://i.imgur.com/7Oh3nus.jpg)

Mercilessly sealed the MDF with two coats of PVA adhesive and avoiding using any wet-and-dry sandpaper - so none of the warping I had in the last stages of the carbine.

Various bits of Foamex cut, sanded and scored for the relief detail

(http://i.imgur.com/2KtsRHf.jpg)

And the cylinder at the back - I used the washers-over-Foamex trick I found out while making the big carbine - lined up the washers on either side of the gun, filled in with Foamex and filler and then sanded around the edges until the washers stopped me...

(http://i.imgur.com/6BaRiuJ.jpg)

(Greeblies on this were a couple of bits of model kit sprue, a piece from a bathroom pull-cord switch and the ridged pipe at the back of the barrel was a bit of corrugated tubing from a water butt cut down the middle and wrapped over the PVC pipe of the barrel.)

(http://i.imgur.com/C4yUVIk.jpg)

Ended up diverting from my original plan for the pistol as I wanted to make sure that the pistol was thin enough to still fit in the thigh holster - hence more detail on the right side, a simpler design on the left.

First pass of grey primer...

(http://i.imgur.com/Ro9Y2lq.jpg)

(http://i.imgur.com/ewxbWeD.jpg)

(http://i.imgur.com/pVH9sSH.jpg)

(http://i.imgur.com/QBojQH4.jpg)

With the thickness of the primer it's now a tight fit in the holster, but then again, I'd rather that than having it slop around...

(http://i.imgur.com/w0mv5KW.jpg)

Next steps - use very fine sandpaper to polish it to a glassy finish - part of what I want to do with this project is to get as close as I can to an utterly seamless machined finish just using the limited set of tools I have in my workshop.  (And certainly what I'd need to do if I ever decided to build props and cast them.)

Happy New Year folks!








Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Jan 02, 2017, 12:53 PM
As always, you do beautiful work!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jan 02, 2017, 01:08 PM
I love watching you work, vod.  It's an inspiration to a still-newbie, and slightly ham-handed guy like myself.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 23, 2017, 04:02 AM
 >:(Thanks dude - loving the new profile pic!

Well, after several layers of silver, black, scratching back, dirt washing, etc,etc (oh and changing the thing down the barrel as the cotton reel I'd put in there decided to crumble)...

(http://i.imgur.com/wapAriW.jpg)

(http://i.imgur.com/GTjWpWU.jpg)

(http://i.imgur.com/cRdUZ9I.jpg)

(http://i.imgur.com/QJpHM4E.jpg)

...which means (I think) all I need to do now to make my kit eligible for urban assault brigade is to build some kind of breaching charge for it.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ajoliveira on Jan 23, 2017, 04:13 AM
Wow vod, your work and skills, damn m8, speechless  8)  ;)

AJ
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ryi'nock on Jan 23, 2017, 07:23 AM
Aayyy glad to see your back boss. Loving the blaster!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Jan 23, 2017, 11:10 AM
loving the new profile pic!

Thanks!

And your pistol is looking really sweet!  I can't wait to see what you come up with for breaching charges.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 23, 2017, 01:14 PM
Thanks.

Discovered an interesting way to get that distressing - sprayed the silver on top of the primer, then sealed that with a gloss varnish.  (Let each coat cure for 24 hours before applying the next.)  Then, on the third day, I sprayed the whole thing with matte black, let that dry for about 5-10 minutes, then lightly scuffed the edges of the whole thing with fine grit sandpaper, concentrating on the corners and high points.  At that stage I also slid it in and out of the holster a number of times.  The result - more realistic scratch patterns that I could achieve with masking fluid.

As goes weathering - after I'd let the matte black cure, I picked out the key silver highlights with a little dry brush of silver - just to make them pop.  Once that had dried, it was dirt washing - a very thin black wash that I rubbed off pretty quickly, then a few blobs of burnt umber (see the brown mark that's to the front of the trigger guard), raw sienna in odd places - let 'em dry, rub 'em back.  Then, drizzle some cold espresso coffee in a few places and let it dry - it really looks like drizzles of oil.

Finally, the whole thing was hit with a satin varnish - which gives it that 'just oiled' look.

Certainly there's something to getting a bit of subtle colour variation in there with the smudges of browns/siennas- it seems to lift everything from just flat matte black paint with a few silver highlights to something that looks more believably made of metal.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Jan 23, 2017, 01:47 PM
Brilliant work as always sir.  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Jan 23, 2017, 05:11 PM
The clear coat between layers trick really does help, especially on plates as you can weather each layer so higher layers have 3D old painted over blast marks and scratches when you get in close.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Jan 24, 2017, 09:51 AM
Some good advice I'm going to have to pocket. Good work as always  :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 12, 2017, 12:47 PM
Well, here's an update on my building - lately, finally working out how to mount the Kal Dagger I built ages ago on my right shin and also, going back to finish off the Clone Wars Commando Droid style Vibroblades I began when the LFL weapons ban came in around the time that Force Awakens came out.

Started the dagger sheath build with a card mockup:

(http://i.imgur.com/T4ict2Z.jpg)

And attempted to make it using a backplate made of Foamex with a sheath made of flattened out, heat-formed PVC pipe...

(http://i.imgur.com/Q2SuCQI.jpg)

Unfortunately, screwing the plate onto the shin caused the PVC to crack and even 2 part epoxy refused to stick it...

(http://i.imgur.com/T9IVgkl.jpg)

Back to the drawing board, I went with Foamex...

(http://i.imgur.com/A8aeIOi.jpg)

A backplate heat formed to match the shin with bolts passing through it into the shin plate, a sheath formed into a long loop glued to it with 2 part epoxy and then the gap between filled first with a combination of kneadable epoxy putty and then P38.  An old ALT key from a keyboard added as a greebly to the front.

(http://i.imgur.com/pzJzCRh.jpg)

The result...

(http://i.imgur.com/eTTj2V5.jpg)

(http://i.imgur.com/XAjLZt2.jpg)

To do - paint, Rub'n'Buff, add dirt washes and add a leather strap to hold the dagger in.  Just awaiting delivery of a 'Sam Brown stud' from eBay to allow me to allow the strap to fasten.

In other news, I went back to my Commando Droid-style Vibroblades.

(http://i.imgur.com/DHibH9d.png)

For the bar that goes across the top of the blades I found I had to order some 5mm PVC rod (thank you, Trent Plastics) and fashioned the rest of the details using some black corrugated PVC pipe from a water butt and the innards of, my old favourites - liquid soap dispensers...

(http://i.imgur.com/Qb4xj4I.jpg)

To give the corrugated detail rigidity and to allow it to fix firmly to the blade, I repurposed a metal rod from an old paint roller extension, cut it to size and cut a slot in it..

(http://i.imgur.com/fX23jGK.jpg)

To attach the other end, I drilled a hole down the end of the rod with my Dremel, cut the head off a screen and pushed it into the rod.

(http://i.imgur.com/drVTm5W.jpg)

Then, a combination of garden wire and 2-part epoxy securing it to the blade...

(http://i.imgur.com/zhknFtd.jpg)

Next up - forming over the end of the rod with kneadable epoxy putty and then P38 over the top of that.


One interesting tip about cutting the MDF for the top of the blade - I used a metal ruler, a box cutter and a bit of patience...

I was concerned about trying to cut a really flat line over the top of the blade with a jig saw - especially because I also wanted to leave tabs to go into the corrugated section of the rod and to secure the rod at the hilt end.

So, I got out my metal ruler, a fresh box cutter blade and repeatedly scored the MDF.  With a bit of persistence I eventually cut all the way through and ended up with an edge much straighter than I would've been able to achieve with any of my other hand or electric tools.

Not recommended in most other circumstances, but I'm pleased to say it IS possible to cut through MDF with a knife if you have to...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Feb 12, 2017, 01:18 PM
Looking good vod! I like the shin mounted knife for sure!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Feb 21, 2017, 11:53 AM
Well, here's a quick update...

Shin knife is sorted...

(http://i.imgur.com/RJ54q87.jpg)

(http://i.imgur.com/hg8jF4a.jpg)

I could only buy 'Sam Brown' screws in pairs, so I reworked my thigh holster with the same leather strapping and fastening as the shin knife...which I think looks far more authentic...

(http://i.imgur.com/qp0jOqR.jpg)

And the vibroblades have now been filled and sanded a few times and are now ready for metal base coats...
(memo to self - cut off the ends of the sticks so they don't stick out quite so far...)

(http://i.imgur.com/QyKdJUP.jpg)

Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Feb 25, 2017, 10:15 AM
As always, just wow.   ;D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 02, 2017, 01:37 PM
Okay, so here's the rest of the work - finishing off the Vibroswords...

Silver spray paint with coat of gloss lacquer over the top...

(http://i.imgur.com/21ZlAVQ.jpg)

Then a topcoat with masking using masking fluid.  The topcoat was so effective at sealing over the masking fluid, merely rubbing it with my fingers wasn't doing a very good job.

So, I scrunched up a bit of kitchen foil and rubbed over the paint - which not only saved my finger-ends, but actually did a great job of scratching back the paint in a very effective manner...

(http://i.imgur.com/T9a7th7.jpg)

I'll be using this trick again because it creates lots of micro-scratches around the edges of the masking and makes for a more natural worn effect.

Various different overbrushings with silver/gunmetal on parts of the rod above the blade and it felt like I was in the ballpark of the Clone Wars swords...

(http://i.imgur.com/XvkjeUu.jpg)

(http://i.imgur.com/DHibH9d.png)

However, in the real world, it looked like something was missing...

So I cut two pieces of black Foamex, engraved some lines into them by pressing down with the back of my box cutter knife blade, heat formed them...

(http://i.imgur.com/tWEdYWt.jpg)

And glued them to the handles as grips, choosing not to paint them as the black Foamex has a subtle texture on its surface that paint would've hidden.

(http://i.imgur.com/RDQj71I.jpg)

After that, it was time to get out the aluminium tape...a trick I'd wanted to try out after seeing it on one of Adam Savage's Tested videos (https://www.youtube.com/watch?v=O1--0DLJv-8 (https://www.youtube.com/watch?v=O1--0DLJv-8))

(http://i.imgur.com/Rxagvur.jpg)

The foil goes down pretty easily if you take your time and it's quite forgiving when it comes to overlapping it.

(http://i.imgur.com/Hzd82w6.jpg)

And within a half-hour, both swords were done...

(http://i.imgur.com/1javwcd.jpg)

Finally I took some wire wool and rubbed it along the length of both blades giving the blades a brushed aluminium effect which also helped to conceal the edges of the tape.  And after that, dirt washing and pulling out the highlights with a little Rub 'n' Buff...

(http://i.imgur.com/nRTCypA.jpg)


So, if there's ever another LFL weapons ban, we're armed and ready!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Mar 02, 2017, 02:03 PM
Awesome work as always. I need to go back through your WIP and just make notes of everything. Wealth of knowledge
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Mar 02, 2017, 03:46 PM
Vod you could cast and sell those. I'd buy one!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 02, 2017, 04:09 PM
Thanks Den. Must admit learning to mold & cast is on my list of things to learn next and I was thinking of starting with something simple like my knives, pistol & swords.  I'll keep you posted!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Torolf Goran on Mar 02, 2017, 11:20 PM
The vibroblades look great and the foil-tape is a nice touch. I'll have to try that on my next blade.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Dar'manda on Mar 02, 2017, 11:42 PM
Thanks Den. Must admit learning to mold & cast is on my list of things to learn next and I was thinking of starting with something simple like my knives, pistol & swords.  I'll keep you posted!
Awesome!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Aden Banto on Mar 03, 2017, 01:57 AM
I'd also be interested if you do start selling those swords. Very nice  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 08, 2017, 12:49 PM
Thanks!

Looking into how to cast and mould things now but just updating you all one what I've done with the start of this thread...

I've added an index of bookmarks to the very first post so we can all skip to the relevant posts! (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1371465#msg1371465)

Which'll save me a big job trying to trawl through it to answer a Ruus'alor type question, and maybe you'll find helpful too!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Raestin Ke'Varek on Mar 08, 2017, 05:16 PM
Thanks!
I've added an index of bookmarks to the very first post so we can all skip to the relevant posts! (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1371465#msg1371465)

I can't tell you how helpful this is, thank you!!  I use your thread all the time, as it's probably my favorite repository of build info on the boards.  This makes it so much easier to navigate now.   8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: OriKad on Mar 10, 2017, 03:16 AM
Just a note to help out everyone else:  Instead of aluminum tape you can also use spray glue and heavy duty aluminum foil.  It has the same end effect and you can cover wider areas without having to worry about visible seams or overlaps.  The tape, however, should be your first choice because it's a heck of a lot easier than spray glue and foil as the adhesive is already there and evenly spread and you don't have to worry about it drying too fast (I've had that problem).  You might also do the same with mylar sheets if you need a little curve and a mirror-like finish, since mylar has some stretch to it.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 10, 2017, 03:19 AM
Good tip - I have managed to minimise the seams along the blade but they're still there...they hold up on camera though. Since it's the first time I've tried this trick I hadn't thought of foil but I'm tempted to try that now! Thanks!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 24, 2017, 03:50 AM
Made  a start on learning how to mould & cast with my Kal Dagger...

(http://i.imgur.com/1pFsJaC.jpg)

I've cast them in black resin so with a little Rub 'n' Buff and a weathering wash, they're ready to go!

(http://i.imgur.com/tjF7CFK.jpg)

Going to work out a costing for them should anyone be interested and I'm looking into building and casting more stuff.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Apr 24, 2017, 11:30 AM
Syko, have you considered going through your WiP and breaking down the posts for your various pieces as individual tutorials?  That way the Tech Team could sticky them, and they could then be more easily accessible to a wider audience?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Apr 24, 2017, 01:32 PM
Syko, have you considered going through your WiP and breaking down the posts for your various pieces as individual tutorials?  That way the Tech Team could sticky them, and they could then be more easily accessible to a wider audience?

We would more likely have them converted to new posts than to link inside of a WIP. There are plans in the works for tutorials overhaul, currently unknown ETA
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 24, 2017, 02:44 PM
Happy to do something like that - Hik'aari - if you can let me know where would make sense to create a whole bunch of posts, I will happily run through and do that.  Get the ball rolling with some content that can later be organised/moved into a folder rather than waiting for a grand scheme to be realised.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Apr 24, 2017, 03:56 PM
I shall pop you a PM and get the ball rolling
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 03, 2017, 04:59 PM
If anyone would like a casting of my Kal Dagger, here's the thread I've started in the Trading Station...

(http://i.imgur.com/AWbZIYI.jpg)

Syko's Props - UK-based Resin Cast Weapon & Hand Props (http://mandalorianmercs.org/forum/index.php?topic=133365.0)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 08, 2017, 05:03 AM
Well, a little update on things...

Had a wonderful time trooping at Legoland Windsor's Star Wars Weekend...

(http://i.imgur.com/PcTs9L3.jpg)

And, along with the Rebel Legion, Joker Squad & Sentinel Squad helped raise £15,000 for a children's hospice.

But sore spots from wearing my kit all day prompted me to make the following modifications.

First, knee attachment...

(http://i.imgur.com/UTEif3b.jpg)

These things were chafing my knees after a long day. So I did some research and found a thread on the Dented Helmet that was showing different attachment methods. 

So now, I've put a strip of industrial Velcro along the inside of the knee, loosened off the elastic strapping and moved it up so it's more in-line with the top of the knee.

Seems more comfortable - the snap still acts as a locator (no twisted knees!), the Velcro both holds the knee in place and acts as padding, and the strapping, not only sits higher, so it's not pulling the plate downwards towards the back of my knee joint but is much easier to deal with as it simply doesn't have to be so tight.

Ultimately, I'm thinking of taking the next step and building some fibreglass knees which will be lighter, stronger and roomier.

Secondly, I took the Dremel to my left gauntlet.

It's been a constant niggle just around my wrist bone since the wrist section is absolutely 100% exactly the size of my wrist and no more...

(http://i.imgur.com/oRRQVh4.jpg)

So I gritted my teeth, and shaved a couple of hollows into the Foamex...

(http://i.imgur.com/93HmXsb.jpg)

Aaaah...sweet relief!

And finally, some cool news, my first International order...

(http://i.imgur.com/yuSmDYS.jpg)

Three read-to-troop Kal Daggers heading off to our Canadian brethren!

Really enjoying working with new materials - silicone & resin (Thanks Paul & Dom!) it's firing off all manner of ideas for upgrades and opportunities for me to share around more of the things I've made through the Trading Station.

Title: Re: Armour Planning & WIP for 2 of us
Post by: levvan on May 08, 2017, 11:11 PM
hey, do you mind if I use your gauntlet images on page 25? I've been looking for some, as my photoshop skills aren't the best.

Also, both of your kits look incredible!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 09, 2017, 04:20 AM
Thanks levvan,

and no, not a problem at all - that's why I posted them.

Would love to see how they turn out!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Laaran Kar'ta on May 15, 2017, 11:58 PM
I've been boasting about you vod  :D all the cali noobs are probably going to start following you now  :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 16, 2017, 07:14 AM
Thanks Laaran!  Great to have you aboard - if you have any questions, please fire away and check out the table of contents of this WIP (http://mandalorianmercs.org/forum/index.php?topic=93907.0)  - there may be links to some tips that can help.

Oh, and if you want to support me, check out Syko's Props on the Trading Station (http://mandalorianmercs.org/forum/index.php?topic=133365.0) - I'm happy to ship internationally. It'd be great to see more peeps rocking the Kal in the USA.

Little update from me - just finished work on game #3 and had a few days vacation.  So I decided to try out a technique I haven't done before - making a pepakura helmet.  I'm using the Rafal Works Helmet Templates (http://www.thedentedhelmet.com/f23/rafal-works-helmet-rwh-v2-helmet-templates-build-45938/) which seem to be the most screen-accurate (down to the assymetry) templates for a canon Boba Fett helmet.

The intention - to make myself and Jayne, lighter resin & fibreglass helmets that are more in proportion, and, allow me to take a shot at casting a canon Boba helmet too, because, well, making one of those would be cool.

Progress, so far...

Print everything out on 200gsm paper and paste with PVA to 2mm pasteboard...

(http://i.imgur.com/3GZWW8O.jpg)

Cut all the bazillion pieces out...

(http://i.imgur.com/OWbZR7m.jpg)

...which left me with sore hands for two days after!

(http://i.imgur.com/AqIlUCH.jpg)

Glue together using CA glue...

(http://i.imgur.com/PASZGaJ.jpg)

(http://i.imgur.com/lymsjbX.jpg)

And finally paint with resin...

(http://i.imgur.com/56uteJ4.jpg)L]

Currently in-hand, taking a variety of rasps, files and filler to it to kick it into shape.
The intention - to create a good set of masters from which I can then create a mould and cast a number of helmets from.

More pics as I make more progress!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Sto-Las Amari on May 16, 2017, 10:44 PM
Magnets on the gaunts is such a good Idea!!! Great work Vod :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on May 17, 2017, 01:00 AM
Looking great on the new scratch build.!
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on May 17, 2017, 08:28 AM
nice to see you got round to experimenting  with casting, those kal daggers look great. still think you could make a killing if you could do casts of your 1313 carbine or a version of it. as always your an inspiration mate, well done.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 17, 2017, 10:02 AM
Thanks guys!

Helmet is progressing pretty well - learned a few things about pasteboard v Sintra/Foamex:

Pasteboard is cheaper, of course, and has the advantage that it can be bent and glued in place with superglue without all of that messing around with a heat gun.

Downsides:
When making small cuts/adjustments, the material tends to crumble and split
When aggressively sanding because resin only penetrates so far it's possible to rip into the board.  So I've gotten into the rhythm of sanding, painting on some resin to the busted up board and then going back and re-sanding.

But pleasantly happy with progress - first time I've sculpted a dome but trusting in my tools and sanding from every possible angle, it's not as hard as I'd feared - though I certainly wouldn't want to be starting a new kit from scratch this way without all that I've learned over the course of this past couple of years.

An interesting thing about the new Boba-proportioned helmet is that it has a deeper dome than our skate helmet builds - which means our eyeline is naturally in-line with the horizontal of the T-visor.  Our original builds are fine but both of us have found we tend to tilt our heads forwards to look through the T.

As goes Trading Station stuff - my plan is to steadily expand range on the Trading Station so I can afford tools (including a 3D printer) to ultimately build a 1313 carbine kit.  At the moment, I'd have to cut it into pieces to cast it as there are lots of undercuts and layers in the original.  So if I can build one that's designed to be cast and assembled...we'll be rocking (and likely, I'll have a lighter version to lug around!)

Laters, guys!  Have a good one!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on May 17, 2017, 10:36 AM
Looking at scratchbuilding one myself! I'll be keeping an eye on this as usual.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 23, 2017, 01:07 PM
Here's an update on the scratchbuild...

Some serious filler and file work got me to here...

(http://i.imgur.com/bJ3ZeAX.jpg)

Which I then sanded back down again and painted a second coat of resin over the top...

(http://i.imgur.com/Dpv08M5.jpg)

The second coat of resin was to re-saturate the exposed areas of pasteboard where the sanding had taken away the original top-layer. 

Having a love-hate relationship with pasteboard - small splits appearing, etc.  But finding a bit of CA glue and a quick spray with accelerant cures most of those problems...

(http://i.imgur.com/vUkiJoR.jpg)

But, the cleanest set of key slots I've ever cut - I used some 1mm thick card and that was definitely easier than my previous attempts in Sintra/Foamex...

(http://i.imgur.com/GnKWBh0.jpg)

I think if I ever do this again, I'll use 2mm pasteboard for a lot of the build, but certainly keyslots and cheeks/mandibles I'll use 1mm - much, much easier to shape manually than the 2mm board and since I'll be moulding and casting from here, I don't need to worry about structural integrity so much.

Then it was another round of primer...getting closer...

(http://i.imgur.com/5sjzxqZ.jpg)

But still beset by little places where the top surface of the board gets sanded back...

(http://i.imgur.com/dbSbPBB.jpg)

So up to today and another, smaller application of filler and some gentle sanding to do...

(http://i.imgur.com/XLqPxVD.jpg)

And looking at the overall shape, I've noticed that the part of the helmet's base behind the ear caps comes in a little too much, meaning that the sides that the ear caps will sit on isn't flat.  So, because I'm moulding, I've put in a piece of wood to just push the sides out to correct the issue.

(http://i.imgur.com/uUsjB2D.jpg)

I think this issue arose mostly because the RafalFett template's inner forms extend below the height of the helmet, making it easy to drift a little.  But, aside from that tiny tweak, everything seems to be going pretty good.

Birthday last week and my gift from Jayne (Nikjay) was all the resin and other materials I'll need to get at least 3 castings done - going to go coldcast aluminium, reinforced with a mix of fibre glass strands & carbon fibre particles.

As I mentioned before, I intend to upgrade both our helmets to something more canon and I really want to make a ROTJ Boba helmet for the shelf. 

Still musing on how to make the rangefinder stalks.  Might have to make a purchase or three, but, as ever, would really much prefer to learn how to cut 6.8mm aluminium myself!







Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 05, 2017, 12:55 PM
More progress....

(http://i.imgur.com/4r1NmOf.jpg)

The brow triangles proved more difficult than I thought they would.

I opted to cut the triangles all the way through the helmet so I could get flat files on the edges.  The problem of getting a flat surface inside the indents was the thing that took most attempts. 

First attempt was to merely backfill with filler - that failed (too lumpy), after that, laying in a triangles of paper and coating with resin (they wilted), then laying in a triangles of card and coating with resin (too rough) until finally I cut out two triangles of plastic, laid them in and finally I was done.

(http://i.imgur.com/4huhDBL.jpg)

I spent some time adding flat platforms to the sides of the helmets for the earcaps - I cut a single piece of thin card for those and underlaid them with multiple thin layers of paper and thin card to compensate for shape of the helmet.  It worked surprisingly well in the end and only required a layer of resin, a bit of sanding and some filler to finish them both off.

(http://i.imgur.com/8IdIDL6.jpg)

I decided to sharpen up the edges of the brow with a bit of filler - successive rounds of sanding had gradually smoothed away the edge...

(http://i.imgur.com/JPKPMqh.jpg)

Oh, and the mustard colour?  That's filler primer - I've discovered Autotek here in the UK (https://www.amazon.co.uk/Autotek-AT000FP500-500ml-Filler-Primer/dp/B004ZJIM8O/ref=sr_1_2?ie=UTF8&qid=1496681173&sr=8-2&keywords=filler+primer (https://www.amazon.co.uk/Autotek-AT000FP500-500ml-Filler-Primer/dp/B004ZJIM8O/ref=sr_1_2?ie=UTF8&qid=1496681173&sr=8-2&keywords=filler+primer)) They do a good regular primer and a filler primer - approximately £5-£6GBP for 500ml - really good stuff.

So finally, after much fiddling, I got all the parts (except for the rangefinder topper which I still need to make) built, primed and ready...

(http://i.imgur.com/KxlxVwL.jpg)

Now I'm into the process of building moulds for everything...

(http://i.imgur.com/pMA1Hrp.jpg)

Simple flat moulds for the larger parts.

But due to an undercut on the right ear top layer I'm having to make a 2-part mould, as I am with the rangefinder stalk:

(http://i.imgur.com/yEtzZcG.jpg)

The reason I'm making the rangefinder stalk 2-part is that I intend to cold cast it in aluminium, strengthening it with an aluminium tube down which, if all goes to plan, I'll be able to run wires.

Just starting work on prepping the helmet too - I've put plasticine behind the keyhole slots but, because I really don't fancy the prospect of having to cut them out again, I've pushed back the plasticine so that *hopefully* I can capture the depth of the keyholes and all I have to do is then cut off the extrusions on the inside of the helmet.

(http://i.imgur.com/QH84oND.jpg)

(Update - 17 July 2017 - this worked an absolute treat - exactly as I'd hoped - all I had to do was sand the keyslots from the inside and the keyslots were revealed - 30 seconds with a needle file was all that was needed after casting to finish up the slots!)


Fingers-crossed.  Hopefully in the coming weekend I'll be able to start moulding the helmet itself.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 21, 2017, 04:30 AM
So, moulding began with me securing the helmet to a board.

I made a card tube that fit inside the helmet and lifted it off the board and then filled around it with plasticine level to the edges of the helmet so that my mould would have an inside lip.

I also created a card wall around the outside to contain the silicone...

(http://i.imgur.com/nMrF1Hu.jpg)

Many, many layers of silicone later I had my mould...(here's some in-progress shots before I'd added all the keys)

(http://i.imgur.com/I5djQuB.jpg)

(http://i.imgur.com/bMSn5GG.jpg)

...a bit lumpy, but I've been repurposing all the leftover bits of silicone left in cups, cutting it up with scissors (I've just invested in a £10 hand meat grinder that does a better job of turning silicone into little chunks)

I also used an egg tray for making my mould keys, repurposing silicone scraps and a small amount of liquid silicone...

(http://i.imgur.com/EcCGFyd.jpg)

That done, I built a 'mohawk' from used egg tray plastic and aluminium tape and covered everything with mould release and then after that had dried, slathered the whole lot with PVA glue (a good thick coating)

Then, a very stinky weekend, outside, covered head-to-toe, wearing a respirator fibreglassing...

(http://i.imgur.com/ZzRC1zA.jpg)

Trickiest part was covering over the mould keys (maybe should've made them a little smaller) but I eventually figured a technique of using long, thin strips of matting and criss-crossing them over the keys rather than trying to lay squares over them...

(http://i.imgur.com/rDqfCpI.jpg)

Moment of truth came when the whole lot had cured and I'm pleased to say it demoulded pretty easily..

(http://i.imgur.com/qd9Catu.jpg)

Finally, 10 x 8mm bolts with wingnuts to keep everything in place...

(http://i.imgur.com/8AcnvxP.jpg)

And I'm pleased to say my first rotocast was successful - the mould has no bubbles or defects and that reflects in the casting...

(http://i.imgur.com/k6kEDoi.jpg)

I now have one master set of everything to make a screen-accurate (dentless) Boba helmet except for the rangefinder tops which I just need to finish sculpting and moulding.

(http://i.imgur.com/aCr9Bd7.jpg)

Did take the opportunity of doing this, my first-ever rotocast of experimenting with ways of reinforcing - I rotocast 2 layers of resin and the third layer I created a mix of resin, fibreglass strands and fillite and brushed that around the mould.

While that worked as a method of getting a composite into the helmet, I have learned a lesson - do this in a few batches - the resin kicks so quickly that it's impossible to get full coverage across the whole inside of the helmet in time.

I followed up with 2 more rotocast layers of resin - pleased that the outside looks 100% on the money, but the inside, due to the reinforcement not being even enough meant that the interior isn't as even as I'd like it to be...

(http://i.imgur.com/jDCiMIL.jpg)

Not complaining, though - everything in this long process worked out perfectly - I just need to get a few opinions/advice to help me work out this final finishing/reinforcing step and then it's new buckets for me and Mrs P!

Would be interested how other folks reinforce their buckets - I'm using polyurethane casting resin throughout and the reinforcing layer on the next helmet I'm going to do in stages using a mix of resin, fibreglass strands and carbon fibre powder.

Does anyone use polyester resin + fibreglass for their helmets, is it possible to reinforce a polyurethane rotocast with polyester resin + fibreglass without it delaminating/there being any reaction between the two types of materials...

And finally, if you do use polyester resin for your helmets - how do you deal with the smell?  I've had to keep the mould out of the house since I created the fibreglass shell since it still stinks and I don't fancy trooping with my head inside an enclosed bucket that stinks like that!

Thanks!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Jun 21, 2017, 05:44 AM
You have been busy :o

Good work, for the PU resin buckets I have I believe they are just straight PU. But its multiple layers as must be at least 8mm. I shall try to remember to measure tonight.

Vassk (from Poland) does cast helmets. May be worth shooting him a message about it
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Jun 27, 2017, 08:46 PM
My first thought is WHAT IS THAT PINK MONSTROSITY AND WHO MADE THAT!! Second observation revealed it to be an inside out mold  :laugh: :laugh: :laugh: Great work as always brother.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jun 30, 2017, 02:23 AM
Thanks Kol!

Well, Photobucket's change in terms has hit my account...
Time to re-up photos to a better service, rebuild links and delete that account.

(And this weekend start cold casting some new helmets!)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Jun 30, 2017, 04:38 AM
Thanks Kol!

Well, Photobucket's change in terms has hit my account...
Time to re-up photos to a better service, rebuild links and delete that account.

(And this weekend start cold casting some new helmets!)

Imgur will be the recommended photo hosting site. The photo posting guide (http://mandalorianmercs.org/forum/index.php?topic=73613.msg1622030#msg1622030) covers the use of Imgur. An update to this guide is due in near future.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 03, 2017, 01:23 PM
Well, I've sorted myself with imgur and will endeavour to go back and update this thread over time.

But, had  a great time over the weekend cold casting my first helmet proper...
(http://i.imgur.com/4GhT4ta.jpg)
(http://i.imgur.com/YEO4Et8.jpg)

Pleased also to be able to pull off setting a hollow aluminium tube inside the rangefinder stalk, so I'll have stability and strength as well as a hollow stack to feed wires

(http://i.imgur.com/zlaP6uC.jpg)

Outside is cold cast aluminium Polyurethane resin with inner layers of PU resing + milled carbon fibre, and then a layer of Polyester resin + fibreglass with milled carbon fibre

After a little chat with the brilliant support guys at Tomps.com where I get my supplies from, turns out that PU and Polyester resin can play nicely together so I've got the super-crisp casting and aluminium finish from the casting resin and the strength from the inner layers of Polyester + fibreglass

Milled carbon fibre (although very dusty - use respirator, do it outside) proved to be a great additive as it's really light by volume, strengthens both kinds of resin (doesn't stop the Polyester from wetting out the fibreglass) and makes the interior of the helmet and awesome black colour...

(http://i.imgur.com/36qN9fb.jpg)

Time to let the bucket sit in the window and warmth to help that polyester smell cure its way out, do some tidying up on that raggedy bottom edge and do some assembly...

Oh, and cast more helmets - one for Jayne, possibly a couple to turn into Boba ROTJ helmets for display, and if I can get the process down...to put on the trading station





Title: Re: Armour Planning & WIP for 2 of us
Post by: Kryamla Redalur on Jul 05, 2017, 12:45 AM
Looks great!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Reyn Vok'chi on Jul 06, 2017, 04:27 PM
Truly awesome brother, well done  8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 07, 2017, 03:24 AM
Thank you, I have been listening to the advice of some masters of the craft  ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Jul 07, 2017, 07:48 AM
very nice work mate. 8)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 17, 2017, 09:33 AM
Pleased to say that the casting process is getting refined...getting a nice consistent cold cast finish and steadily reducing the weight - first cast came out at 1kg, second one I've reduced weight down to 800g while the helmet still feels nice and stable.

Current process is:

1. Cold cast layer of aluminium powder + Polyurethane casting resin
2. Layer of milled carbon fibre + Polyurethane casting  resin
3. Rough sand interior and wipe down with acetone
4. Layer in strips of fibreglass edging tape + fibreglass matting with mix of Polyester resin + milled carbon fibre
5. Layer in a second strip of fibreglass edging tape around the rim of the helmet to add extra strength and thickness at the bottom
6. Thin coating of Polyester resin + milled carbon fibre to smooth interior and fill in any small gaps

This seems to give me the best of both worlds - I can get a really nice metallic finish by lining the mould with aluminium powder then slush casting the PU casting resin + aluminium mix - no air bubbles or anything, then, with the polyester + fibreglass layers I can get more strength for the weight than I could with PU resin alone.

(I tried polyester gel coat as the first coat but found it took longer than slush casting to get the first coat in and that it kept getting bubbles in all the awkward corners despite all the brushing and poking I did - also, brushing in meant that I couldn't get the fine layer of aluminium dusting into the mould, I had to rely on what was in the gel coat.  I may attempt this again some time, but this method seems to be working nicely for me at the moment.)

(http://i.imgur.com/g3780GX.jpg)

That's two new helmets for me and Mrs P, one in-progress that I'm going to convert and paint as a canon Boba for myself.


(After that, casting a fourth to paint as a canon Boba for sale, and then, I'll start offering helmets on the Trading Station.)

Rangefinder stalks working nicely and all the ear parts fit as they should.
(http://i.imgur.com/DwV1p46.jpg)

Right ear cap cover attaches with magnets:

(http://i.imgur.com/5Bz6GDH.jpg)

Method of attaching rangefinder topper with magnets - recessing magnets so that they lock into topper.
(http://i.imgur.com/vCMSbeF.jpg)

I have bought the necessary parts for the flashing LEDs on the rangefinder, along with a mercury switch so I can make it a self-contained unit, rather than running wires into the bucket down the stalk.

So, yes - for me, the third helmet to finish fibreglassing, clear casting of the rangefinder topper inserts and then begin cutting out visors, installing interiors and painting the new buckets.

In the background here, I'm restoring the links for my WIP after ditching Photobucket - if there's anything you'd like me to make a priority to upload, PM me, I'll seek out the relevant pics.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Jul 17, 2017, 10:44 AM
I love the additional "POP" you get from pre-powdering the mold. Glad you gave it a go and it turned out well for you :)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 17, 2017, 11:51 AM
Thanks.  Yep - made a real difference!

I've found that if I pour the initial slush into the mould over the visor area (which'll be cut out, of course) it reduces the risk of washing away the pre-powdering.

I've also found that pre-powdering the ear caps gives similarly great results but I have to be very careful about getting anything but a thin coating of powder in the mould - any small clumps actually prevent the resin from seeping through so on de-moulding there are holes where the clumps have been.

Final bit of learning - after going over the parts with super-fine wire wool, a cloth and some Brasso brings it to another level - Brasso is slightly abrasive so that really brings out the shine.  (Apparently car products like T-Cut do the same.)

And other pro-tip :) - to patch small holes and bubbles, I've found that if I collect the dust from sanding away flashing on parts, a small blob of super glue pushed into the hole and a bit of resin dust is an easy and quick way to patch.  I push the dust into glue until it's a big thick blob, hit it with some accelerant, sand it down and repeat if necessary.




Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jul 20, 2017, 12:59 PM
In progress update.

Two buckets now cast, rangefinders and ear caps added.  Just received delivery of a bunch of welding visors, so that'll be the next step before painting.

(http://i.imgur.com/tiR7RKP.jpg)

Learning how to clear cast polyester rangefinder inserts - a little bit of learning to do to ensure things are bubble free and experimenting with tiny amounts of wax additive to ensure that any parts of the casting that meet with the air aren't left slightly sticky.  (Far right = too much wax!)

(http://i.imgur.com/imRMvuY.jpg)

So soon will be able to offer cold cast ear caps + reinforced rangefinder, black resin rangefinder topper with a clear resin insert on the Trading Station.  Here they are before clean-up and polishing:

(http://i.imgur.com/puaxMPE.jpg)

And finally, I discovered SHOULDER SCREWS to attach the Rangefinder after my attempts to attach with regular screws kept coming loose.

(http://i.imgur.com/1c4nAQ3.jpg)

I did a bit of Googling to discover that these are specifically designed to create pivots that don't unscrew - basically the smooth part goes right through the hole, into the helmet and I've packed it with a number of washers so that the nut can be tightened completely on the inside.

So, next up on the agenda - finish fibreglassing the interior of helmet #3, install visors in #1 & #2 and then start painting them up!



Title: Re: Armour Planning & WIP for 2 of us
Post by: drrkscott on Jul 27, 2017, 12:08 PM
Wow! Am in awe of your "tin lids". When my Sabine-mad daughter's an adult will have to revisit your WIP to see if can replicate this excellent work!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 07, 2017, 05:57 AM
Thanks fella.  Must admit, I've learned from your WIP already.

After seeing what you'd done with the Sabine build, I decided to buy a couple of Portwest Slip Ratchet Helmet Harnesses (https://www.portwest.com/index.php/slip-ratchet-safety-harness) from eBay...

To add ours to helmets, I cut and bent some pieces from a strip of aluminium, drilled holes to match the attachment points on the harness and used epoxy to glue the 'female' parts of Chicago screws to them...
(http://i.imgur.com/FaJwYnX.jpg)
(The quarter of smaller holes I drilled so that the glue/resin would seep through them.)

Once glued in place and test fitted, I then put a strip of fibre glass tape and resin over them to secure them...

(http://i.imgur.com/4CRERuC.jpg)

The result - our helmets are now fitted with removable helmet harnesses that are comfortable, distribute the weight nicely across our heads and have better airflow than the padding that was in the original.  A plus also is that the helmets are much more stable and less likely to 'bobble' than our originals.

(http://i.imgur.com/rzv5Zl5.jpg)

I also got the visors installed - using Chicago screws epoxied to the helmet and held in place by a stack of rubber washers...

(http://i.imgur.com/0deAPN3.jpg)

I experimented with the visor material and found that it plays nicely with a heat gun, so rather than forcing the visors into place (which we had done in our original helmets) this time, I was able to heat form them to the outside of the helmet and lay them in with far less of a struggle...

(http://i.imgur.com/rk048kP.jpg)

So, now this is what our dining room looks like...

Two new helmets, ready for painting for Jayne and me, two additional ones that I'm going to assemble and paint up as canon Bobas and another one curing for sale to a friend who's keen to become a Merc.

(http://i.imgur.com/fC73f62.jpg)

Am working out pricings on making more of these helmet kits for the Trading Station (thinking 1 budget version in grey polyurethane resin, 1 deluxe version in cold cast aluminium with all the hand-laid fibreglass & c/f reinforcements)

I'd like to offer visors too, but am trying to find a UK supplier of sheet polycarbonate/similar so I can build more without the wastage that comes from repurposing welding visors.

And in tangential news, I've cracked the cold-casting/reinforcement of the rangefinder stalks - here they are with a slim brass tube running through for reinforcement and channelling of wires.  If anyone wants any making up, PM me...I'll get a Trading Station post up soon.

(http://i.imgur.com/3H5VePL.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Aug 07, 2017, 09:08 AM
hi simon, put me down for a hollow range finder stalk when you start production pls. everything is looking really nice, well done mate.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 07, 2017, 09:58 AM
Thanks fella.  PM sent!
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Aug 17, 2017, 04:17 AM
well i got my range finder stalk and.... it's the bomb mate!!! fantastic work. thankyou so much. 8) 8) 8) can't recommend this product enough.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Aug 17, 2017, 01:53 PM
well i got my range finder stalk and.... it's the bomb mate!!! fantastic work. thankyou so much. 8) 8) 8) can't recommend this product enough.

Does this mean we might start getting you toward a place of approval :D (I need to get someone else in Kent an OM. I have been the only one in this County for too long now)
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Aug 17, 2017, 02:53 PM
lol i'm getting there slowly mate. :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Aug 17, 2017, 03:38 PM
Oooooh...stay away from my money!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Daxar Arkada on Aug 17, 2017, 06:47 PM
ranger finder stalks that can be wired? Color me interested...
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 18, 2017, 03:54 AM
Drop me a PM!  Trying to get time to update Trading a Store post properly
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ruus bal'Neta on Aug 18, 2017, 04:20 PM
Question on the Shoulder Screws. How do they differ from using a Chicago screw? Does the smooth barrel part of the screw spin around the screw itself?
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 19, 2017, 05:49 AM
Sorry, I'm not a super-expert on screws I just did a bit of research on Google. :)

The smooth portion of the shoulder screw doesn't spin around, it's just designed to be the axle for whatever's attached.

I don't how they would compare to a Chicago Screw as I don't know if you can get Chicago Screws that are long enough for the purpose.  Also, I don't know if the Chicago Screw's design might allow for traction that would cause them to come unscrewed more easily than something that has been specifically engineered and designed to create an axle.

But they're pretty cheap - I picked up a pack of 4 for a few pounds on eBay and immediately saw the difference between them and trying with a conventional bolt.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Ashen Kelborn on Aug 19, 2017, 11:44 AM
Sorry, I'm not a super-expert on screws I just did a bit of research on Google. :)

The smooth portion of the shoulder screw doesn't spin around, it's just designed to be the axle for whatever's attached.

I don't how they would compare to a Chicago Screw as I don't know if you can get Chicago Screws that are long enough for the purpose.  Also, I don't know if the Chicago Screw's design might allow for traction that would cause them to come unscrewed more easily than something that has been specifically engineered and designed to create an axle.

But they're pretty cheap - I picked up a pack of 4 for a few pounds on eBay and immediately saw the difference between them and trying with a conventional bolt.

To answer your question, Chicago screws would unscrew, its why a drop of superglue is generally needed to stop it happening.
the shoulder screw you showed holds position at the ends where tension is and the smooth body allows movement like you described  ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 21, 2017, 11:40 AM
Okay folks, an image-heavy helmet painting post.  Uploading everything so maybe it's useful to anyone new here.

Quick summary of how I do my paints/weathering/dirt washing...

Mask off the bits that you want to keep metallic and paint on the first layer of masking fluid (in this example a blast pattern with streaks emanating from the centre)  I apply masking with a Q-Tip...which as it gets clogged is good for loading with small amounts of masking fluid and using the irregular edges of it to get fine-line streaks and irregular blotch patterns.

Once masking fluid has gotten at least tacky, a quick spray of hairspray and throw on some rock salt.

(http://i.imgur.com/hptc9Zb.jpg)

Spray on your first coat of faux primer, leave it to cure then peel off all the masking (I'll use my fingers, a hard eraser or a scrunched up piece of aluminium foil to coax the more stubborn bits of masking away)

(http://i.imgur.com/vOXFYPt.jpg)

Then apply more masking/hairspray/salt, painting over the original exposed metal area and adding on an irregular border to mask over some of the first layer of faux primer.

Spray over second coat of faux primer and take off the masking...
(http://i.imgur.com/kcjZ5El.jpg)

And finally the same again - masking, hairspray, salt and your top coat of paint...

(http://i.imgur.com/bn8qvgA.jpg)

Then after it's all dried, the masking's been cleaned off, apply a dirt wash - in my case I use Payne's Grey, Burnt Umber, Burnt Sienna, a splash of Yellow Ochre acrylic paints and some cold Espresso coffee - applied randomly and rubbed and cleaned back.

In the case of this 'blast mark' I applied a lot of Payne's Grey in a radial pattern, let it sit for a while and then rubbed back putting more effort into the centre than I did at the edges...

(http://i.imgur.com/NkLEBjl.jpg)

And here's the helmet from all angles as I decided to document building up the paint job...

(http://i.imgur.com/TCUxiSe.jpg)

(http://i.imgur.com/GEqbMHx.jpg)

(http://i.imgur.com/CIhdSmM.jpg)

(http://i.imgur.com/luz1cgf.jpg)

(http://i.imgur.com/VPQHAfS.jpg)

(http://i.imgur.com/HlK4niv.jpg)

(http://i.imgur.com/ynmf7IT.jpg)

(http://i.imgur.com/XMkk7Bf.jpg)

(http://i.imgur.com/DHnkE8J.jpg)

(http://i.imgur.com/9PE30id.jpg)

(http://i.imgur.com/FCh1jS1.jpg)

(http://i.imgur.com/TjWKpfU.jpg)

(http://i.imgur.com/fxEkCWu.jpg)

(http://i.imgur.com/zQhcgIK.jpg)

(http://i.imgur.com/t71a8Ql.jpg)

(http://i.imgur.com/m92mwhr.jpg)

(http://i.imgur.com/cqM0pZ0.jpg)

(http://i.imgur.com/rH3jtVb.jpg)

(http://i.imgur.com/Z0jM8PU.jpg)

(http://i.imgur.com/rN92GTp.jpg)

(http://i.imgur.com/G8WrQsn.jpg)

(http://i.imgur.com/wlrHsez.jpg)

(http://i.imgur.com/Y0jHAiW.jpg)

(http://i.imgur.com/ggbbj43.jpg)

And finally, the whole thing - Syko's helmet MK II - finished...

(http://i.imgur.com/lglfezC.jpg)

(http://i.imgur.com/hgMDLhr.jpg)

(http://i.imgur.com/O6DM2tU.jpg)

(http://i.imgur.com/HMKlfzC.jpg)

(http://i.imgur.com/YcPeP22.jpg)

Mercury switch + Flashing LEDs + coin cell hidden in the R/F topper works a treat - no need for running wires down the stalk (although I could if I wanted) but it means the R/F topper can be pulled off/knocked off/removed without trauma

(http://i.imgur.com/ivcMCdA.jpg)

(http://i.imgur.com/S5ljiUc.jpg)


So, there we are - first ever cold cast + fibre glass + carbon fibre scratchbuilt helmet finished!

Now - time to start masking up Mrs P's and get it ready for our next troop on 2nd September.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Boxception on Aug 21, 2017, 05:34 PM
Yup..... I'm jelly now.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 22, 2017, 11:33 AM
 ;D

Thanks to several recommendations I've used some 3mm smoked grey perspex to create a new visor for Jayne - advantage being that it's a little easier to see through than the polycarbonate welding visor.

Having played around with glass cutters the best results I've got for cutting it was with the following type of jigsaw blade - I understand that there are some specialised acrylic cutting blades but couldn't find any with a U-shank to fit my jigsaw.

The whole process went pretty smoothly - kept on the protective film for cutting and as well as heatforming.

After cutting I put the heat gun on it, evenly heated it and shaped it to the inside of Jayne's helmet.

(http://i.imgur.com/WWwytD2.jpg)

If anyone wants to pick up the same kind of perspex in the UK - here's the link: https://www.trentplastics.co.uk/acrylic-plastic-perspex-sheets/tinted-acrylic-perspex-sheets-sub/tinted-acrylic-perspex-sheets (https://www.trentplastics.co.uk/acrylic-plastic-perspex-sheets/tinted-acrylic-perspex-sheets-sub/tinted-acrylic-perspex-sheets) - 3mm smoked grey is what I used.

Title: Re: Armour Planning & WIP for 2 of us
Post by: Aden Banto on Aug 22, 2017, 12:07 PM
By far the best method of weathering I've seen! Impressive!  :o
Title: Re: Armour Planning & WIP for 2 of us
Post by: Hik'aari on Aug 22, 2017, 12:45 PM
After cutting I put the heat gun on it, evenly heated it and shaped it to the inside of Jayne's helmet.

Putting it on a baking tray (greaseproof paper optional) in the oven at 130-150 DegC is a good way to really evenly heat visors.
Temp and time depend on your oven, but within 5 minutes it should start becoming flexible enough to take out and put straight into the helmet and shape.

I had to do this as I have actually curled the central portion of the visor to keep it from squashing my nose.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kris Jasra on Aug 22, 2017, 03:27 PM
Given the potentially slightly more see through nature of these on their own - they work well when paired with reflective coating.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 28, 2017, 05:38 PM
Finished Jayne's new helmet...

(http://i.imgur.com/qBy2K9L.jpg)

(http://i.imgur.com/xsfdyx4.jpg)

(http://i.imgur.com/9NsgZ6e.jpg)

(http://i.imgur.com/zKe9v2f.jpg)

So we're ready for next week's troop for the Nottingham Hospitals Charity  (http://mandalorianmercs.org/forum/index.php?topic=138263.0)

Plus I finished the helmet I'm donating to Feel the Force Day

(http://i.imgur.com/PxnLF4x.jpg)

Discovered that cold cast aluminium, brushed up with fine wire wool + Brasso looks pretty badass, but if you then take the teensiest bit of Silver Rub 'n' Buff to select sharp edges it takes it to another level entirely.






Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Aug 28, 2017, 06:31 PM
That's awesome!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kryamla Redalur on Aug 28, 2017, 07:09 PM
Wow! Impressive!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 29, 2017, 04:38 AM
Thank you, guys.

Just one more thing - I've updated my section on the Trading Post where I'm now selling cold cast and slush cast helmets, r/f kits and other goodies

Syko's Props - UK-based Helmets, Ear Caps, R/F Kits & Hand Props (http://mandalorianmercs.org/forum/index.php?topic=133365.0)
Title: Re: Armour Planning & WIP for 2 of us
Post by: jett drexel on Aug 29, 2017, 09:46 AM
any plans to do a resin version of the 1313 carbine yet mate? :P :P :P
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Aug 29, 2017, 09:50 AM
One day! 

Just been able to afford a 3D printer kit and am beginning to assemble it.

If it works, hopefully that means I can build more complex and interesting greeblies (that will not get applied to anything until they're cleaned up and don't look like they're 3D printed) ...and then maybe make a 1313 kit that's designed for casting.  (Right now the current one would lock a mould within seconds and likely weigh 5kg of solid resin!)

Probably knees and gauntlets next though - both of mine need significant improvement, especially the knees (super uncomfortable still)

:)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Sep 01, 2017, 08:49 AM
Here's some comparison pics of our new mkII versus the monstrosities that were our original skateboard-helmet scratchbuilds...

(http://i.imgur.com/YX6l8er.jpg)

(http://i.imgur.com/EULnNgD.jpg)

(http://i.imgur.com/W1DUUgj.jpg)

(http://i.imgur.com/9ZfF73Q.jpg)

(http://i.imgur.com/gA67XQb.jpg)



(http://i.imgur.com/hWcRSxh.jpg)

(http://i.imgur.com/Psb6heW.jpg)

(http://i.imgur.com/zCxD1Yk.jpg)

(http://i.imgur.com/2eFdPjO.jpg)

(http://i.imgur.com/MeeV4GC.jpg)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Sep 01, 2017, 10:05 AM
Looks like your helmets got hit with a cartoon mallet!  :laugh: Kidding of course vod, you guys make great stuff and it's just getting better!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Sep 01, 2017, 10:22 AM
Absolutely.  First time I've put them side-by-side!

Biggest difference is the depth of the dome.

We used skate helmets as a base on those.

The problem that a shallow dome causes is that you end up tilting your head forwards a lot of the time to see through the visor which until you've tried on a Boba-proportioned helmet you don't appreciate.

Also - putting the helmet harnesses in is so much better than padding - they really move with our heads, there's far less 'bobbling' and there's more airflow around the inside of the helmet as a result.

Oh, and it's nice looking at the ear caps and not immediately seeing all the sauce bottle lids and bits of plastic chopstick... ;)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Dec 22, 2017, 04:56 AM
Wow..what a crazy year.

It's been non-stop since I started selling helmet kits, and building helmets for other folks has absolutely obliterated all the time I could spend working on my own kit or interacting here on the site.

So much so that I've decided to retire the moulds (a few pieces of the key-slots started to come away during the last pull) I made back in May and am just about to create a whole new set for 2018...

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

After that, it's a few castings and fingers-crossed, over the holidays use my newly assembled 3D printer kit (Anet A8) to design some cool new props for my kit that I intend to mould and cast and share with everyone else.

Happy holidays, everyone!  Hope to get more time here on the forums in 2018.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 02, 2018, 01:16 PM
Sooo..I ran out of silicone on the 23rd and I'm still waiting for those lovely folks at Tomps to get back to work so I can get my hands on a bunch more of that pink rubbery stuff.

In the meantime, I set myself a holiday challenge to get back into some complex 3D modelling in Blender3D and make a start on a prop that I've been wanting to try for quite some time - a probe droid that can house a GoPro and can be carried around or mounted on an acrylic stand so that taking photos while trooping is possible.  (At Legoland last year I carried a GoPro set to timelapse in a small pouch I'd made for my belt - the results were terrific.)

So here's the 3D model and the first few parts coming out on the printer...
(https://i.imgur.com/z0QH3Ot.jpg)

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

(https://i.imgur.com/frgbQw3.jpg)

Fingers-crossed it works as I'm hoping, and if I can get it to functionally work, I'd love to cold cast it...and if that's a success...create a few kits for the Trading Station.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Jan 08, 2018, 11:33 AM
Oh I'm really gonna have my eye on this!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Obey Wann on Jan 11, 2018, 01:53 PM
In the meantime, I set myself a holiday challenge to get back into some complex 3D modelling in Blender3D and make a start on a prop that I've been wanting to try for quite some time - a probe droid that can house a GoPro and can be carried around or mounted on an acrylic stand so that taking photos while trooping is possible.  (At Legoland last year I carried a GoPro set to timelapse in a small pouch I'd made for my belt - the results were terrific.)...


...Fingers-crossed it works as I'm hoping, and if I can get it to functionally work, I'd love to cold cast it...and if that's a success...create a few kits for the Trading Station.

If you are successful, please PM me. I have a GoPro 4 that I would love to encapsulate in a probe droid shell. Very interested!!!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 12, 2018, 05:39 AM
Thanks, guys! Will do. 
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Jan 24, 2018, 12:38 PM
Quick update...

(https://i.imgur.com/NgjRQY2.jpg)

Took about 80 hours of printing, I guess (several days) and I now have my own custom model kit to build - lots of sanding to do, not only to get the striations out from the 3D print (coated with XTC3D to help smooth out some of the lines, and to strengthen everything) but also some of the polygonal facets caused by me making a lower poly model than perhaps I should (that said, some of the geometry was hard enough to construct with fewer polys, having 4x more to deal with would have been...special...)

Also on the other track...

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

Brand new helmet mould complete - time to take it for a spin with some test castings...

Title: Re: Armour Planning & WIP for 2 of us
Post by: Malakier Vhett on Jan 26, 2018, 10:31 AM
Man i fell waaay behind on this. I love seeing what you come up with.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Mar 20, 2018, 05:53 AM
Been super-busy making helmets for the Trading Station and delighted to hear that folks are happy with what I'm making.

Finally gotten time to work on another thing I want to mould and cast for myself and then, all being well get out there.

KNEES!

My knees are the most painful part of the kit and have been modified after every single troop.

So, I've been busy with Blender and the 3D printer to finally make some (as screen-accurate as I can make 'em, but without the signature Boba damage) ROTJ-style knees.

First prototype:

(https://i.imgur.com/9ILoqgh.jpg)

(Knee plates were too flat and symmetrical)

Second prototype - featuring the asymmetrical 'tags' on the outside backs of the knees that are seen in

(https://i.imgur.com/WQq0I2C.jpg)

Lots more filling and sanding (which I don't mind, since all the really hard work is done in Blender and I can make things with the Anet A8 to accuracies that are tighter than I can with my bare hands)
(https://i.imgur.com/CqoaNVK.jpg)

...to the finished plates:

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

Next-up - working out the best way to affix the darts so I can model the darts and the plates that will stick behind the holes in the knees

Plan is to ultimately cold cast and fibreglass them, and follow through with an idea Reyn had mused about a while ago - installing aluminium strips into the knees to help them keep their strength.

(Probe droid is still ongoing but has taken a back seat as it's super-fiddly and contains MANY parts - good learning exercise for Blender and 3D printing but requiring lots of work to finish)
Title: Re: Armour Planning & WIP for 2 of us
Post by: Bowfanny on Mar 20, 2018, 08:37 PM
That’s awesome, you never cease to amaze Vod!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Mar 21, 2018, 12:42 PM
ooooh, nice knees.
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 16, 2018, 09:01 AM
Made a little 3D printed upgrade last week and gave it its first outing with the Joker Squad SWG costuming group at Leamington ComicCon over the weekend.

Still working on the large "GoProbe" Probe Droid model, but I'm figuring it'll be a long time before I get to finish it off, so I decided to take a faster route to equipping my kit with an in-universe, concealed body cam.

Designed in SketchUp since I knew it didn't need much modelling, I worked to come up with a Swarzy Greebly that would fit around a GoPro Hero3+
(https://i.imgur.com/rvyKj6H.jpg)

Printed out the pieces in black PLA...
(https://i.imgur.com/ZJBlShl.jpg)

Coated with XTC3D, sanded back, patched with Vallejo plastic filler...
(https://i.imgur.com/cFDXBQv.jpg)

Magnets to attach the 'lid' that conceals the on/off button...
(https://i.imgur.com/8gEFTA9.jpg)
(I chose not to make the front button accessible or allow the LEDs to show through as I figured that would make it look too much like a GoPro and the lights would attract more attention.)

Then a strap that was leather where it's visible, velcro behind where the camera goes and elastic where it's hidden - estimates were slightly off so I had to double-loop the elastic to make a tight enough fit...
(https://i.imgur.com/etcEGuH.jpg)

Test fitting behind my collar plate:
(https://i.imgur.com/BcVntmu.jpg)

Paint job comprising last-minute, Friday night Rub'n'Buff, dirt wash and both switches painted with acrylic paint with clear nail gloss to add shine.  Also, big dollop of clear nail gloss in the fake 'lens' and leave it overnight so the nail gloss can self-level and cure...
(https://i.imgur.com/kfqAFKT.jpg)

Final assembly:
(https://i.imgur.com/Jhq2FoC.jpg)

After my experiences at Legoland last year, running a similar set-up, I simply set the GoPro to take photos every 10 seconds - then when I got home, picked out the cool ones, did a bit of cropping - here's a sample:

(https://i.imgur.com/lZp9y0Y.jpg)

(https://i.imgur.com/QW8OOJ2.jpg)

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

And here's how it sits on my kit...(cool pic courtesy of Benni Hartigan of Joker Squad SWG)

(https://i.imgur.com/i3hbpjy.jpg)

I'm working on another type of belt mount for Jayne so we can be our own photographers at Legoland in a couple of weeks.

If anyone's interested in a 3D printed kit PM me.  Contemplating putting these for sale on the Trading Station if I get enough interest.





Title: Re: Armour Planning & WIP for 2 of us
Post by: Havelock on Apr 16, 2018, 10:33 PM
That's awesome!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on Apr 16, 2018, 10:34 PM
Very very nice!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on Apr 24, 2018, 05:20 AM
Thanks guys!

Soo...I've been trooping a number of times with the lovely Reyn Vok'chi and the last time (trooping at the Notts Children's Hospital at Xmas) I figured out why just being around him (apart from his killer costume and great personality) feels like you're in the presence of Clint Eastwood in The Good, the Bad and the Ugly...

As Reyn walks, his kit makes clinking sounds - the kind of which you subliminally associate with the sound of heavy bits of armour and weaponry or the spurs in a Western movie.  It's hard to notice, it just 'is' and it's tricky to pinpoint...  I finally figured out what it was - a small bolt in each boot heel and a couple of washers - simple, but INCREDIBLY effective at providing an air of baddassery - the kind of foley that would be added in a movie to enhance a character's presence.

So, I finally got time to make this mini upgrade - I took a couple of strips of aluminium, bent them in a D shape, drilled a bolt through my Foamex heel plates and dropped on a bunch of washers and split rings that when I take a step make just the right kind of clinking sounds.

Then it was a bit of a paint job and dirt wash to match them into my boots...

(https://i.imgur.com/Bsh3kDP.jpg)

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

These are obviously close-ups, but the strips, from a distance/standing around the costime conceal what's going on while leaving enough open space for the sound to get out.

Clink....  Clink... Clink... 
Title: Re: Armour Planning & WIP for 2 of us
Post by: K'iim Tal on Apr 24, 2018, 01:40 PM
Great idea :D
Title: Re: Armour Planning & WIP for 2 of us
Post by: Lusiphur on May 05, 2018, 06:34 AM
that...is........GENIUS!
Title: Re: Armour Planning & WIP for 2 of us
Post by: Syko Voss on May 11, 2018, 10:26 AM
Thanks folks - works a treat and makes you feel like a baddass outlaw while you're striding through crowds on a troop.

Here's the latest builds:

Decided to build a belt-mounted Go Pro Hero box for Jayne's belt...

Built in SketchUp, as before, doing all I could to keep the Star Wars aesthetic...
(https://i.imgur.com/Zx3FWBl.png)

3D print in black PLA, once again printing the details separately so they don't merge in/lose detail while sanding and finishing...
(https://i.imgur.com/MX0rNcw.jpg)

(https://i.imgur.com/nwD3DVi.jpg)

Paintjob...
(https://i.imgur.com/9MdO2BG.jpg)

Access to top button to stop/start
(https://i.imgur.com/y7mpkKb.jpg)

Velcro and webbing loop....
(https://i.imgur.com/s3fzwgJ.jpg)

And here's how it looks on the belt...
(https://i.imgur.com/zkL11Ua.jpg)

Worked reasonably well at Legoland but I need to tweak a tiny degree by adding a little padding under the GoPro's bottom edge to stop it pointing towards the ground - too many shots with folks' heads cut off!

That said, the shoulder mounted GoPro did me proud - link to gallery here: https://www.facebook.com/simes.phipps/posts/10156189337409566 (https://www.facebook.com/simes.phipps/posts/10156189337409566)

Also, I've now ordered a bunch of leather strapping to get rid of the elastic strapping behind my knees, calves and to add a bit more to my thigh plates, along with a stack of black cotton twill to make a new  flak jacket  that opens at the back like Jayne's (mine takes too much adjustment with its open sides), plus it removes some of the pleather from my kit as I switch it over to real leather...

(https://i.imgur.com/Tfu4EmE.jpg)

And in other 3D printing/modelling news...

Went back to the source of the Rogue One book and built a version of the Death Trooper grenades:

(https://i.imgur.com/qG57sGk.png)

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

(https://i.imgur.com/oBl8Xox.jpg)

These, I believe are closer to the screen used ones than the model that's on Thingiverse (https://www.thingiverse.com/thing:1953285).  I intend to clean up, cold cast them and put three on my left thigh to replace my original grenades


Title: Re: Armour Planning & WIP for 2 of us
Post by: Kol Varek on May 11, 2018, 02:22 PM
None of these will do. Best you send these to me for disposal  :P amazing as always.