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[stonewall]

Well helmet is well under way, Jet pack well under way and now the armour is underway.

 Thank's to WoF who was kind enough to scale up plans for a 6ft 5 individual. I finally got around to starting this and being brave and doing it in Aluminium.

 So photos.....

"Plans are Afoot"


The first cut, so NO turning back now!


Torso Armour all cut out.


FRONT


REAR


So started but a long way to go.

So quick questions.

A, Best way to attach Aluminium armour to vest?
B, What is the best way to tackle the groin armour?

Look forward to input from you guys.

[Tact Kor]

Nice start!

I've never attached aluminum but I assume you could use the same methods as plastic; Velcro, Screws/bolts, rivets, or snaps.

As for the Cod piece you can use the same WOF templates.

 I used 1/8" Sintra for the main triangle part folded it to shape then glued a 1/4" piece of Sintra on top to give it the thickness, for aluminum I would try cutting out the upper cod piece in wood them bend the aluminum over it to create a 3D form, you'll need to cut out "darts" for the round edges, the main part is just a triangle shaped piece, you can cut "darts" out on the lower section in order to bend it back underneath.

I hope that gives you some help, good luck.

[stonewall]

Thank's Tact Kor.

  Would love to keep the groin aluminium too but yeah bit wary on that LOL  As said Never done an armour build, let alone one in this material.

The reason for choice on Aluminium, was simple really. Most events I do I have to travel via train (occasionally a lift), so wanted to make it sturdy as I will be wary enough over the lid and jet pack as it is LOL
 Plus the weathering/battle damages to the armour will only Add to it I think being Aluminium.

[Tact Kor]

I'll try using it some day, but for now I know I'd just ending cutting my hands as I don't have much patience 

It looks like it is a challenge to work with and should give you a nice kit once done, I 've seen other members using it so reach out to them I am sure they can share some tips.

[stonewall]

Thanks again Vod.

[Nate Jangotat]

Looks good bud - once you have bent to the shape of you body. worth testing the size to see if any trimming required before painting up

Keep at it

[Raist Kebi'cin]

Looking really good

What thickness aluminum are you using?

Cos im tempted too try this too

im book-marking you so no pressure 

[Niabi]

Nice start vod

tape the plate to you so we can check the size

[Thaxos]

Off to a good start.

This:

What thickness aluminum are you using?

And this:

tape the plates to you so we can check the size

[stonewall]

Thanks Guys and hope to do this armour build and character justice..

Will get some tape (ran out) and do a dry fit for you guys

As for Aluminium thickness its 1mm thick.

[stonewall]

Just a quick question to those who have done their armour in Aluminium.

 What is the best way to round the edges off?
I know it will be attached to a leather vest but still, best to round off No?

[Thaxos]

Roll the edges and sand the physical edge to make it blunt.

Rolled edges will give your plates a sense of depth to the metal armor. 

[Peregrinus]

^^^

Kinda like you see in this post in my WIP thread. It was, in my opinion, a very good thing they did when sculpting and vacu-forming the original armor for Episode V -- it gives the armor more of a sense of substance, but subtle (almost subconscious) cues also let on that it's not just a thick slab. Things like where the collar and back armor overlap, or the cod and the butt, and you can see the edges. Or the (lack of) depth of the chest display or the emitter in the middle of the chest diamond...

--Jonah

[Dralsya Adén]

I have not done my armor in metal YET, but from I have learned I think bolts would be best. Get a canvas vest and bolt the armor to that would be my suggestion. It looks great vod, your off to a good start.

[Peregrinus]

Bolts are a good technique. Ditto rivets (the hammered kind, not pop rivets). If you don't want something like that interrupting the finish of the plates, you can epoxy rare-earth magnets inside the armor and vest... My approach with mine is to use a good metal epoxy to mount chicago screws (aka screw posts) inside the plates, running through eyelets in the vest. With any approach involving glue points, though, you need to use enough magnets or screw posts that no single one is bearing much load. Over time, that will stress even the best glue joint, and any repair will always be weaker than the initial construction (unless you take it all the way back down and re-do that bit from scratch).

--Jonah

[stonewall]

Thank You for the kind words and advice Vods.

@Thaxos, yeah simples!! Thank You.

@Peregrinus, thanks and checking your wip. Also the extra info on securing the armour to the vest.

@Madhatter, Canvas vest mmm will look into that and the option of bolting the armour.

[stonewall]

Well done a test rolled edge.

Used one of the chest parts so can be compared to the other.

LMK what you think.






 Certainly gave more depth to the aluminium no?

[Dresdon Acacin]

The one thing about rolling the aluminum at this stage is when you go to shape it to your body the rolling will kink: it can be fixed were it kinks but it will resault in hard edges developing were you try to bend it.

[stonewall]

Thanks Dresedon Acacin,

 As said this was just a test run, see if I could do it. Shaping first makes so much sense even to someone like me with no experience at this LOL

[Thaxos]

Rolled edges look good, that's a nice amount to do. Gives enough depth without looking too thick.

[Peregrinus]

Yeah, that looks pretty darn good -- but I'd suggest adding curvature to the plates before rolling the edges, for the reason cited. If you have a blowtorch, you can heat the aluminum at the spot you're working when you roll the edge, so it has some ductility and will stretch and compress where needed to hold that curvature. Look up the thermoforming properties of aluminum for that, as I don't have 'em (I mostly work with stainless steel). And remember to check as you go that the plates' curvature stays where it's supposed to be -- it'll have a tendency to want to flatten out as you roll the edge.

--Jonah

[Niabi]

looks cool to me vod

[jonathansams]

how do you bend the corners, and points...cut slits in it?  Does the armor have to be rounded over like that?

[stonewall]

Thanks guys and the advice too Peregrinus.

 Jonathansams, I just used short thick nose pliers to bend and No cutting at corners, all hand strength. Seems to fold fairly easy tbh.

As for the reason for doing it, it gives depth to the armour. Looks thicker than it actually is.

[Tracyn Ordo]

The extra depth rolling the edges gives the plate looks great! Little bits like that make a big difference to the over all look of the finished kit.