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Jedi Gauntlet Build
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gandalfbmg (Bart German)
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PostPosted: Thu Oct 04, 2012 2:33 am    Post subject: Jedi Gauntlet Build Reply with quote

A local workshop is doing a vacforming class at the end of this month, and I wanted to go to learn, but maybe do something with some costume use right off the bat too. so I'm going to start messing with making the bucks for Clone Wars style Jedi gauntlets...

I have a bunch of the pink insulation foam laying around so I took some measurements from my arm and started cutting:



Next is I know I need to figure out what to coat these in, to protect the foam from the heat and suction of the vac table, and to give me a surface I can smooth out and fill in the gaps (since I'm a terrible cutter and it's a hack job so far on the cutting. So hopefully I'll get some inspiration (or advice) on what routes I can go there...

Please be gentle, this is my first time ever trying anything like this...
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SithariRog (Roger Allen)
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PostPosted: Thu Oct 04, 2012 6:18 pm    Post subject: Reply with quote

Well...have you thought about fiberglass and fiberglass resin? I use that a fair bit. It's messy, but the final product can be sanded and painted very nicely.
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gandalfbmg (Bart German)
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PostPosted: Thu Oct 04, 2012 6:32 pm    Post subject: Reply with quote

SithariRog wrote:
Well...have you thought about fiberglass and fiberglass resin? I use that a fair bit. It's messy, but the final product can be sanded and painted very nicely.

Are you talking about as a cover for the buck, or for the finished armor itself?
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GotWookiee (Matt Pfingsten)
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PostPosted: Thu Oct 04, 2012 7:50 pm    Post subject: Reply with quote

Try foam coat. You can hey it from hot wire foam factory.
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gandalfbmg (Bart German)
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PostPosted: Thu Oct 04, 2012 8:01 pm    Post subject: Reply with quote

GotWookiee wrote:
Try foam coat. You can hey it from hot wire foam factory.


Hmm... never heard of it but sounds promising... Do you know how brittle it is; won't crack when heated or anything?
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SithariRog (Roger Allen)
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PostPosted: Fri Oct 05, 2012 12:41 am    Post subject: Reply with quote

gandalfbmg wrote:
SithariRog wrote:
Well...have you thought about fiberglass and fiberglass resin? I use that a fair bit. It's messy, but the final product can be sanded and painted very nicely.

Are you talking about as a cover for the buck, or for the finished armor itself?


Well, I guess it depends on what your end goal is.

If you want to make one pair of arm armor for wearing, you could use what you have as a main form, make a fiberglass covering or whell...then use the shell as your armor. You would continue the sculpt with fiberglass/bondo, etc. to get the final design...paint and wear it.

Or...you could make a final sculpt, make a mold of it*, then case with fiberglass.

*Some folk made a transfer casting that is used to refine the sculpt to produce a master prop from which another mold is made...from which many castings (or pulls, if you vacuform it) can be made.

Welcome to the world of prop making!
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gandalfbmg (Bart German)
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PostPosted: Wed Oct 10, 2012 2:51 pm    Post subject: Reply with quote

Well, I've finally gotten the 'top' half roughed out. I ordered some of the Foam Coat stuff too and it's on the way. Knowing that I was a little less careful this time so the cuts are a lot less smooth. I'll make it up on the filling/sanding. I'm not quite skilled with the hot foam cutter yet, and it shows...



I do think my plan will be to try and get a good pull from these and use to make a more permanent bucks from, out of a more resilient material.
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SithariRog (Roger Allen)
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PostPosted: Wed Oct 10, 2012 5:37 pm    Post subject: Reply with quote

Oh, I see...you're going to use that as a mold for a vacuform pull with ABS or something similar! Cool!
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Zazarus (David Scheffner)
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PostPosted: Wed Oct 10, 2012 11:41 pm    Post subject: Reply with quote

Hey Bart, what vac table are you using? I know a few people in KC are close and there are a couple in the area but just wondering where you are planning for this one?

But when you do get this read I will be interested in a pull or two as well
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gandalfbmg (Bart German)
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PostPosted: Thu Oct 11, 2012 1:50 am    Post subject: Reply with quote

Zazarus wrote:
Hey Bart, what vac table are you using? I know a few people in KC are close and there are a couple in the area but just wondering where you are planning for this one?

But when you do get this read I will be interested in a pull or two as well

I'm going to hopefully start testing the mold during the vac class at Hammerspace. But once I get the hang of it I'll probably use Andy's.
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Jedi Seever (John Seever)
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PostPosted: Thu Oct 11, 2012 4:29 am    Post subject: Reply with quote

Bart, I too am interested in a pull from this. When it is finished and all.
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Generic Jedi costume progress:
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gandalfbmg (Bart German)
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PostPosted: Sat Oct 13, 2012 3:10 am    Post subject: Reply with quote

First layer of Foam Coat is on.

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gandalfbmg (Bart German)
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PostPosted: Tue Oct 23, 2012 2:23 am    Post subject: Reply with quote

So Zazarus took these to work and went to work on them with the belt sander to try and smooth them out a bit. The stuff proved a little too stonelike, so after a while we decided to do a coat or two of bondo over it and sand it and work it smooth that way, then do a really thin coat of the foam coat after that (now that I've figured out the trick is to getting it on thin and smooth is lots of water Wink ). Though, I didn't have as much bondo as I thought and ran out about 2/3 of the way, and had to improvise with spot putty. So that's it until I can get to the store.

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Zazarus (David Scheffner)
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PostPosted: Tue Oct 23, 2012 2:40 am    Post subject: Reply with quote

I'll try to get the other one on the sander this week. This stuff is like wearing down a sanding pad with another sanding pad.
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gandalfbmg (Bart German)
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PostPosted: Tue Oct 23, 2012 3:11 am    Post subject: Reply with quote

Zazarus wrote:
I'll try to get the other one on the sander this week. This stuff is like wearing down a sanding pad with another sanding pad.

I wouldn't worry TOO much about it; I'm laying the bondo on pretty thick and I like working with it better for flattening out the bumps... I'll just cover ti all anyway.
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