About Us Members Unit Listing Events Costuming Resources Forum Contact Us Trading Cards
 

Forum and Costume Controls

   FAQFAQ  SearchSearch  MemberlistMemberlist   UsergroupsUsergroups  medals.php?sid=78a247d46a20d92490524e6b64d48675Medals   RegisterRegister   ProfileProfile   Log in to check your private messagesLog in to check your private messages   Log inLog in

       
REMINDER: Do not change your e-mail address yourself. Please read this first for why.

General Rahm Kota v2
Goto page Previous  1, 2, 3 ... , 14, 15, 16  Next
 
Post new topic   Reply to topic    Rebel Legion Forum Index -> Costume and Prop Making -> Jedi
View previous topic :: View next topic  
Author Message
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
Rebel Legion CV Supporter (Amount: 1)

PostPosted: Sun Aug 18, 2013 3:00 am    Post subject: Reply with quote

I shaved the edges of the forearm plate down to a decent representation of the CG model's contours and added the raised edging. Had some slightly worse than moderate errors in the edge trim (as in broke it clean through) but will fix it a bit with filler and disguise it with the paint and weathering. The last pic shows the angle cut at the elbow to allow nose scratching and sandwich eating. Smile

I found a reasonable solution to the metallic silver rectangles on the glove fingers. After much trial and error I tried inking them with a silver autograph marker and sealing them with Angelus matte finish acrylic sealer. Without the sealer the ink smudges very easily, but sealed it holds to the deerskin a lot better.

I also got some little neo-D magnets in the mail today that will power the gauntlet closure system.

More to come.






~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
Ky-Wan Zann ()
Active Legion Member


Joined: 03 Jun 2002
Posts: 3139

Medals: None

PostPosted: Mon Aug 19, 2013 10:49 pm    Post subject: Reply with quote

Nice update mate
_________________


'Just because I don't like to fight. Doesn't mean I can't'

'They can be a great people Kal-El they wish to be. They only lack the light to show the way'

'JASON' Detachment
Back to top
View user's profile Send private message Send e-mail AIM Address Yahoo Messenger MSN Messenger
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
CVI Supporter (Amount: 1)

PostPosted: Wed Aug 21, 2013 2:37 am    Post subject: Reply with quote

Great to hear your text, Zann. Very Happy
_________________
Back to top
View user's profile Send private message Send e-mail
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
Rebel Legion CV Supporter (Amount: 1)

PostPosted: Thu Aug 22, 2013 12:36 am    Post subject: Reply with quote

I cut a slightly oversize elbow guard from 2mm Sintra, then took a silicone rubber mold of it on the flat, then poured a urethane rubber model using ReoFlex-40 from Smooth-On. I used an old plastic sheet that I think was for covering a bowl in the microwave and tack-glued it inside the gauntlet assembly with a bit sticking out the elbow end. I wanted a semi-rigid form that would extend the conical curvature beyond the end. I lined up the rubber model and glued it to the plastic sheet, sealing the edges with superglue.

The plan is to mask off the elbow end inside the cone and pour a Hydrocal mold over the rubber elbow guard model. That will give me a smooth mandrel to use for heat-forming the Sintra elbow guard. This will ensure that the curvature exactly matches the inside of the gauntlet at the elbow end.

The top and side edges of the guard will have 1mm raised edging. The bottom (wrist end) edge will be riveted to a curved strip of galvanized steel, cut from a piece of duct-work. The steel strip will have two squares of Sintra spaced out and rivited. The forearm plate will have mating sintra squares spaced to the gaps in the steel strip assembly, each with a super magnet embedded in it, as well as raised keys that mate with the edging on the main assembly. The whole thing should snap into place like a row of teeth.

Stay tuned.





I told you the gauntlets were the hardest element of this costume. Razz

~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
Rebel Legion CV Supporter (Amount: 1)

PostPosted: Fri Aug 23, 2013 1:45 am    Post subject: Reply with quote

Masked it off at both ends.
Poured in Hydrocal.
Pulled out a mandrel.

The Sintra production elbow guard will be heat-formed to shape in that little depression. The cross-hairs transferred from the soft model are a free bonus.






~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
CVI Supporter (Amount: 1)

PostPosted: Sun Aug 25, 2013 10:02 pm    Post subject: Reply with quote

After much trial and error, with no trial and success, attempting to heat-form a Sintra elbow guard, I decided to go with what I know. Taking advantage of the dry mid-70s temps with no sun or wind, I built a 4-layer fiberglass elbow guard.

In the process I discovered an interesting thing. Before I laid in the cloth I was worried about releasing the production cast from the mold, so I sealed the hell out of the plaster, then used some auto paste wax on the mold and polished it up a bit. Not only did the casting release easily, the no-gelcoat back surface was dry as a bone with no tackiness. The wax in the mold reacted just like wax in the resin allowing it to fully cure. I added a couple layers of Bondo icing and sanded it down while in the mold to be sure of the surface curvature.

The contour came out perfect with very little gap . Still missing the edge trim at this point but wanted to test fit the assembly for scaling. The fiberglass material is going to work better for riveting to the galvanized steel plate in the magnetic closure system.

It's starting to look like something.

Come back soon.







~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
CVI Supporter (Amount: 1)

PostPosted: Mon Sep 02, 2013 5:07 am    Post subject: Reply with quote

I added the edge trim to the elbow guard, and took a first cut at the gauntlet closure. I added alignment blocks to the rear of the forearm plate and a strip of galvanized steel to the elbow guard. The square spacers were milled out to hold the magnets. Unfortunately, I accidentally drilled through the center spacer and out the other side. The pix have a nice Photoshop patch over the hole, but I'll have to fill the real one with a fiberglass/bondo plug or else re-do the part. I'm kinda leaning toward the latter as it is rather thick and heavy with its 6-layers of glass. Four or five layers would have been good, and left a bit more flex in the part

The magnets are N52 pull-weight, which is on the better side of the more common N42s, but with just the two (the center one in the pix is fake) it didn't pull against the backing plate as well as I'd hoped. I may end up using 0.75" Dia. instead of 0.5" shown, and just ream out the slot a bit more. The forearm guard will cover the ream-age anyway. Also, the 0.25 thickness is a bit too much as well. I can get 0.20 without epoxy coating and try those.

The glue I used for the metal to plastic bond is LocTite Pro-Line Fast-Grab Premium 8X construction adhesive. Absolutely wicked bond. Gotta clamp it for a few hours though.

After the glue dried I just had to try the thing on. With the neoprene wrist seal under it, the assembly holds pretty tight, maybe too tight. Also it will have to hold 1cm higher on the forearm, and with the TFU1 Kota shirt on it resists any rotation. I'll have to keep the fabric light and the sleeves tight under the gauntlets.

Stay tuned.







~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
Anakin Skywalker ()
Active Legion Member


Joined: 24 May 2009
Posts: 723
Location: Naboo
Medals: None

PostPosted: Mon Sep 02, 2013 9:15 pm    Post subject: Reply with quote

wow o.0 looking good Bill!
_________________


"All who gain power are afraid to lose it."
"The whole thing stank, but our noses had been out in the cold for too long..."
Back to top
View user's profile Send private message Visit poster's website MSN Messenger
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
Rebel Legion CV Supporter (Amount: 1)

PostPosted: Tue Sep 03, 2013 1:51 am    Post subject: Reply with quote

Thank you Kira.
_________________
Back to top
View user's profile Send private message Send e-mail
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
Rebel Legion CV Supporter (Amount: 1)

PostPosted: Sat Sep 21, 2013 7:53 pm    Post subject: Reply with quote

Today I did a rough sculpt of the wrist clip. The photos show I need to adjust the alignment a bit, as well as smooth out the edges and contours. I ended up being off a little on scaling and relative positioning of the forearm plate. It should have been about 0.25" longer and extend by the same amount more toward the hand. It's funny there was just no way to get it perfect without the wrist clip, but the entire assembly had to be completed before the clip could be sculpted. Catch-22. Embarassed

The end result is the wrist clip is a bit shorter end-to-end than it should be, but I'll live with it rather than redo a whole new forearm plate and mounting.

Most of the finish shaping and fitting will be done on the hard model. Will also be able to measure the symmetry and can always re-do the sculpt if corrections are needed. Smile

It slowly rolls forward.







~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
SithariRog (Roger Allen)
Legion Membership Officer
Legion Membership Officer


Joined: 01 Apr 2009
Posts: 3152
Location: Rainbow City, Alabama
Medals: 2 (View more...)
Rebel Legion Supporter (Amount: 1)

PostPosted: Sun Sep 22, 2013 12:21 am    Post subject: Reply with quote

Bill, incredible work, as always!

Are you sculpting to wear or sculpting for a mold from which you'll cast the wearable pieces?

And...what materials are you using to sculpt so far? I think I recognize some foam board? But would be intersted in knowing your sculpting mats.

thanks Wink
_________________

Past Offices: Asst. LMO, Legion Costume Judge, DCO KJO, BCO Tranquility Base
Back to top
View user's profile Send private message Send e-mail MSN Messenger
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
Rebel Legion CV Supporter (Amount: 1)

PostPosted: Sun Sep 22, 2013 3:20 am    Post subject: Reply with quote

Hey Rog,

So far all of the freehand sculpts for this project have been done using oil-based (plasticine) clay for taking a mold then casting a rigid working part, either a wearable part or an intermediate hard model for further refinement and mold-taking for a final wearable (production) part.

Some parts were cut/shaped out of foamed PVC (Sintra) board, then molded and production-cast in fiberglass. Others were cast in soft (rubber) urethane to shape around other pieces, then molded again in silicone and prod-cast in fiberglass. The shoulder bells were molded in plaster, cast in fiberglass, back-filled with plasticine, then re-molded in silicone and plaster for the production bells to be poured from liquid urethane plastic.

The wrist clip shown is plasticine (Klean Klay - which I just now see is no longer available). I will finalize the contours and shape to be very slightly oversize, smooth out the surfaces as best I can, then mask off the surrounding area and spray clear-coat all over it. Then wall it off and make a silicone rubber mold with a 2-pc plaster backing. I will probably use a bit of fiberglass matting or maybe short-strand Bondo-Glass to cast a working rigid model in that mold. That model will be further adjusted (using Bondo and sanding) to fit snug against the narrow point of my wrist where it meets my hand, then another 2-pc silicone rubber mold will be made with intent to pour a hard urethane casting that will be painted, weathered, and worn with the finished costume.

And that only completes the left arm.

Much work.

~ BC
_________________
Back to top
View user's profile Send private message Send e-mail
SithariRog (Roger Allen)
Legion Membership Officer
Legion Membership Officer


Joined: 01 Apr 2009
Posts: 3152
Location: Rainbow City, Alabama
Medals: 2 (View more...)
Philippines Typhon Relief (Amount: 1)

PostPosted: Sun Sep 22, 2013 1:22 pm    Post subject: Reply with quote

Thanks for the info. That's basically how I'm doing my sculpts, only with slightly different materials (same family, different brand and such).

And yes...it's a TON of work, which a lot of people don't understand. But...like you, I think it's super fun.

Looking forward to seeing the next upgrades Very Happy
_________________

Past Offices: Asst. LMO, Legion Costume Judge, DCO KJO, BCO Tranquility Base
Back to top
View user's profile Send private message Send e-mail MSN Messenger
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
Rebel Legion CV Supporter (Amount: 1)

PostPosted: Sat Oct 19, 2013 7:50 pm    Post subject: Reply with quote

Back from NYCC and back on the project.

Since I had to do the clay sculpt directly on the production gauntlet parts, this was by far the most difficult to wall-off and mold. I painted a few layers of Smooth-on Rebound 40, trimmed the edges a bit then used a contour guide to cut out cardboard for walling off the perimeter. Carefully added Hydrocal White plaster in half sections, with vasoline applied to the seams in between halves.

I will stuff some Bondo and glass inside to get a rigid model to work with. I can finally visualize how the piece will be worn and removed. The design is quite remarkable for a CG model. I'll show more detail on what I'm talking about after I take the casting. Also, the palm-side cutout will be done on the rigid model.

More to come.







~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
Koda Vonnor (BillCostigan)
Active Legion Member


Joined: 14 Jul 2006
Posts: 2471

Medals: 2 (View more...)
CVI Supporter (Amount: 1)

PostPosted: Mon Oct 21, 2013 2:34 pm    Post subject: Reply with quote

I laid in some fiberglass yesterday. Thick Rondo coat then 7-8 layers of cloth glass strips then another thick Rondo. I added 2-3 more layers on the wrist side for reinforcement since I will be doing the rectangle cutout. It's fugly for sure, but very solid. Symmetry isn't perfect but I can shape it a lot on the next phase. It won't be worn anyway, just a hard model for taking a shell mold. I have some super strong urethane resin I will use to pour the production piece.

Oh and now that I can examine it closely, I realize I'm going to have to sculpt a second one of these for the right gauntlet. I was hoping to use only one and just pour two from the same mold, but to lay flat against the end of the main assembly the sculpt picked up a very small amount of skew twist. This one will not lay flat on the right assembly. Oh well, practice practice practice. Smile





~ Vonnor
_________________
Back to top
View user's profile Send private message Send e-mail
Display posts from previous:   
Post new topic   Reply to topic    Rebel Legion Forum Index -> Costume and Prop Making -> Jedi All times are GMT
Goto page Previous  1, 2, 3 ... , 14, 15, 16  Next
Page 15 of 16

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot post calendar events in this forum
The Rebel Legion is a worldwide Star Wars costuming organization comprised of and operated by Star Wars fans. While not sponsored by Lucasfilm Ltd., it is Lucasfilm's preferred volunteer Rebel costuming group. Star Wars, its characters, costumes, and all associated items are the intellectual property of Lucasfilm. © 2014 Lucasfilm Ltd. & ™ All rights reserved. Used under authorization.


Powered by phpBB © 2001, 2005 phpBB Group