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Snowspeeder Pilot wrist comm
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Schph Gochi (Phyllis Schulte)
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PostPosted: Fri May 18, 2012 10:04 am    Post subject: Snowspeeder Pilot wrist comm Reply with quote

After teaching myself to sew...leather work...and dabble in many other things...
one of the last things I am trying to learn is mold making and casting.
Casting is the easy part using Smooth-on products rather than resin......hard to screw that up...the stuff is exceptional to work with...
and even making molds is fairly easy...

but making the original to make a mold...whole nuther matter...

So..
I am trying to make a more accurate Snowspeeder Pilot's wrist comm....the one I have is pretty bad (the white piece on the left)...I purchased it..

I am starting to make a new one original that is smaller, more detailed and once done will make a mold of it for casting...







before I go any further (I did do some additional work on the piece last night) I would like to see if anyone has some good screen captures of this piece or any other advice that might be useful before I make the inevitable mistakes...
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DL (Johan Hanson)



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PostPosted: Sat May 19, 2012 1:36 pm    Post subject: Reply with quote

I have not seen the one on the left before. I have another one that is even less accurate.
I used to make one that was a bit more accurate than both (according to me Wink ). I cast a few that I sold (or donated), then I got tired of the resin fumes and gave my mould to Mr Bojangles. I offered it to him because he made other Rebel Pilot items. It was not an exclusive deal; I am giving away moulds for the cost of materials and shipping, provided that the recipient promises to make them available to other people at a reasonable cost.
My comm pad looked like this.
It was attached to the glove with a bolt, nut and a piece of plastic on the inside that matched the footprint of the comm pad. The speaker grille was separate to ease painting and hide the nut.
Mr Bojangles changed the design a bit, using a real metal knob and a piece of readily available perfboard as the speaker grille.

I have no reference picture that is particularly good on its own, but you can get a better idea of how it is made by studying several pics. Here is my best reference picture. If you want others I have, just PM me your email address and I'll send them to you.


I think that the same item that the comm pads were made out of can also be seen in several places inside the Snowspeeder cockpit.
After I hade made my casts, I noticed that the comm pad that the AT-AT drivers are wearing have similar pins as in the front of the Rebel pilots'. There are some good pics of these around ... and they show that the pins are transparent!
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Schph Gochi (Phyllis Schulte)
Nar Shaddaa Base XO
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Joined: 18 Aug 2002
Posts: 12127
Location: Mokena IL
Medals: 11 (View more...)
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PostPosted: Sun May 20, 2012 10:10 am    Post subject: Reply with quote

Many thanks for your insights...
and for the photos....

I am only doing this project as a learning experience/excercise and wanted to start learning out to make originals to be molded by starting with something more on the simple side...a more simple shape...

and since I have a Snowspeeder Pilot costume, I thought that replacing this piece would be a great place to start.

I have done some other mold making and casting.....but I was learning mold making from pieces I already had...just to get the hang of it.

I am using Smooth On products that really produce no fumes and are much more sturdy, have less bubbles, and produce some remarkable results.
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DL (Johan Hanson)



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PostPosted: Sun May 20, 2012 1:50 pm    Post subject: Reply with quote

Schph Gochi wrote:
I am only doing this project as a learning experience/excercise and wanted to start learning out to make originals to be molded by starting with something more on the simple side...a more simple shape...

My interpretation is that it was not that simple. I think that the section with the red square had slanted walls on the side as well as on the front. I made my master from pieces of plastic, including angled pieces for where I needed a 90° angle. I sculpt one of the teeth in the front and then moulded copies that I assembled with pieces of sheet plastic as spacers.

Schph Gochi wrote:
I am using Smooth On products that really produce no fumes and are much more sturdy, have less bubbles, and produce some remarkable results.

I was also using urethane, although of a European brand. Not even near as bad as polyester ("fiberglass resin"), but bad enough for me. I am a bit more sensitive than most, I can get a migraine attack from using the wrong brand of paint.

You have mail. Good luck with your build!
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Schph Gochi (Phyllis Schulte)
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PostPosted: Sun May 20, 2012 8:55 pm    Post subject: Reply with quote

compared to some of the wrist comms and rank badges...
I do still think of it as a more simple design....

I am working with wood for the "master"....
and sanding...sanding....and sanding...
lol...

I did find that perfboard on line and ordered a few....
that was a huge help to find out what that stuff was called...
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Schph Gochi (Phyllis Schulte)
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PostPosted: Mon May 21, 2012 11:30 am    Post subject: Reply with quote

the perfboard...

http://www.circuitspecialists.com/64-8931.html

and...
right now...am laying down several layers of primer
letting them dry really good
and wetsanding in between the layers....
making sure there are no signs of woodgrain...

will post some photos when the paint is dry..

Very Happy
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Schph Gochi (Phyllis Schulte)
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PostPosted: Tue May 22, 2012 10:59 am    Post subject: Reply with quote

As of this morning...
old one vs my new "sculpt"...well...if you can call it that...

and waiting for the perfboard.....

















Hidden under the paint on the tabs on the top is actual copper contacts from a large switch used on Chryslers....I work in service dept. at a Chrysler dealer...so I used an old switch/relay and found them to have a variety of witdth contacts....so I might wire brush the paint off those contacts and expose the copper/metal contacts....
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PostPosted: Tue May 22, 2012 7:18 pm    Post subject: Reply with quote

That looks very nice Phyllis, if you make these available put me on the list. Thumbs up
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Lonescout (Angelo Marcano)
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PostPosted: Tue May 22, 2012 9:01 pm    Post subject: Reply with quote

Looking good!
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Schph Gochi (Phyllis Schulte)
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PostPosted: Tue May 22, 2012 10:00 pm    Post subject: Reply with quote

FallenJedi wrote:
That looks very nice Phyllis, if you make these available put me on the list. Thumbs up



Will do...
my plan it to make them available to people....
some of this stuff is really hard to find...


As soon as I receive the perfboard....and put that on, it should be ready for me to make a mold and then cast in liquid plastic...
not resin...
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Schph Gochi (Phyllis Schulte)
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PostPosted: Mon May 28, 2012 1:04 pm    Post subject: Reply with quote

Well...

I did finish up...

first I applied a piece of the perfboard on top of the sculpt...



wasn't sure I liked that so I made the fatal mistake of carving out the area where the perfboard goes...




I say fatal because I don't have any fancy tools...
I used a hand chisel...which I don't use often and encountered some quality control....




lol..

I made a mold of my sculpt...
and this is what the final looks like...

original and cast from the mold...



I am wondering if I should make a second mold of the piece without the perfboard...
remove the perfboard....
or dig out that area on the cast...
clean up the edges...
and then add the real perfboard to the indentation on the cast...

I did order extra perfboard because, as usual, shipping was just as expensive as the product itself.

It is not great...
but most definitely better than what I had...
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Orion Knight-Star (Alex McKeel)
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PostPosted: Mon May 28, 2012 2:01 pm    Post subject: Reply with quote

make that two of us. I would like one down the road myself.
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PostPosted: Mon May 28, 2012 3:58 pm    Post subject: Reply with quote

This is looking really good. Thumbs up As you mentioned it might be good to have the perfboard simply set in the mold after some clean up.
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Schph Gochi (Phyllis Schulte)
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PostPosted: Mon May 28, 2012 4:18 pm    Post subject: Reply with quote

I am going to try to play around with it some more...

I can do anything I want to the one I cast...

cuz I can always cast another in 15 minutes...

Very Happy

If/when I come up with something better...
I will have to then make another mold.

I know that the holes in the perfboard did not show up well on the mold probably because of the glue used to hold the perfboard in place probably seeped up through the holes and even if that thin layer did not go all the way to the top of the holes in the perfboard (which are tiny)....it still blocked enough at the point of contact to render the holes not as prominent...
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Schph Gochi (Phyllis Schulte)
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PostPosted: Wed Jul 04, 2012 11:24 pm    Post subject: Reply with quote

cleaning house...

I don't think I will get back to this project...
the wrist comm is good...
but far from great...
needs to be smaller...
and was going to toss out these out...
but remembered that two of you were interested in them...

pm me if you would still like them...

will include one of the perfboards...


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