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 Armour Planning & WIP for 2 of us

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Raestin Ke'Varek


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Re: Armour Planning & WIP for 2 of us
« Reply #105 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)

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kiffren


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Re: Armour Planning & WIP for 2 of us
« Reply #106 on: Nov 20, 2015, 07:32 PM »
It's nice to see knees done right.

It looks to me like you might be heating your plastic up too quickly. Have you tried using a lower heat setting and slowly heating it from further away? It would prevent those curled edges and brown (burnt) spots.

Syko Voss


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Re: Armour Planning & WIP for 2 of us
« Reply #107 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.



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...



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:



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



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.



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...



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:



And 2 coats of chrome 24 hours later to finish:



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...



Shaping gently with heat gun....



(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...



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...





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



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...



And chrome...



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...



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.



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...



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



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):



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



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

« Last Edit: Jul 17, 2017, 04:36 AM by Syko Voss » Logged

Ram'or Kranak


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Re: Armour Planning & WIP for 2 of us
« Reply #108 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.

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jett drexel


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Re: Armour Planning & WIP for 2 of us
« Reply #109 on: Dec 11, 2015, 08:36 PM »
an absolute masterclass. :D

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Malek Dair


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Re: Armour Planning & WIP for 2 of us
« Reply #110 on: Dec 11, 2015, 11:16 PM »
Spot on work! Love the tutorials. I learn so much from your stuff here! Thanks vod!

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Armour Thread: http://mandalorianmercs.org/forum/index.php?topic=94290.0

Helmet Thread (COMPLETED): http://mandalorianmercs.org/forum/index.php?topic=95445.0

Soft Parts: http://mandalorianmercs.org/forum/index.php?topic=107583.0

Gauntlets: http://mandalorianmercs.org/forum/index.php?topic=114126.0

Education and armor, self defense, our tribe, our language and Our Leader All help us Survive

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Simmy_82


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Re: Armour Planning & WIP for 2 of us
« Reply #111 on: Dec 12, 2015, 07:36 AM »
This is just awesome. Some serious skills vod. Top drawer skills.

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WIPs
Helmet - Complete
Armour - Complete
Soft Parts - Complete
Weapons - Complete
Gaunts - Complete
Re: Armour Planning & WIP for 2 of us
« Reply #112 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  :)


kiffren


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Re: Armour Planning & WIP for 2 of us
« Reply #113 on: Dec 12, 2015, 11:25 AM »
Well done on that cod plate. How much does it weigh?

For shoulders I just form them over a 4" piece of aluminum pipe.

Syko Voss


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Re: Armour Planning & WIP for 2 of us
« Reply #114 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!

Syko Voss


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Re: Armour Planning & WIP for 2 of us
« Reply #115 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.



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.



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...



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...



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



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!

 





« Last Edit: Jul 17, 2017, 04:39 AM by Syko Voss » Logged

Kavryn Falco


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Re: Armour Planning & WIP for 2 of us
« Reply #116 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.

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Kotyc solus guyani, a mirdala solus shukala.
The strong one survives, but the clever one conquers.

Build & upgrades | Hurty things | K.O.V.A. #15 | M.A.R.S #7

Syko Voss


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Re: Armour Planning & WIP for 2 of us
« Reply #117 on: Dec 25, 2015, 08:35 AM »
And here's the state of our kitchen table before I cleared it for Xmas dinner...




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



1/12th scale Bandai Boba Kitt!

Happy Holidays, everyone!  ;D




« Last Edit: Sep 13, 2017, 04:10 AM by Syko Voss » Logged

Kavryn Falco


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Re: Armour Planning & WIP for 2 of us
« Reply #118 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

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Kotyc solus guyani, a mirdala solus shukala.
The strong one survives, but the clever one conquers.

Build & upgrades | Hurty things | K.O.V.A. #15 | M.A.R.S #7
Re: Armour Planning & WIP for 2 of us
« Reply #119 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

 


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