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Possible B-wing Pilot Helmets...
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Soraken Bolt ()
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PostPosted: Fri May 03, 2013 5:16 pm    Post subject: Reply with quote

The smooth cast products dries to a very solid plastic and does not need any additional support. If you are slush casting a piece, once a layer is dried you can add additional layers to get the thickness you want.

I have made a number of one and two part molds with their rubber products and have cast blasters and some pieces I'll be using for my Endor Commando bandolier. I will be slush casting the head piece for my Lobot in the next month or so. There are a number of tutorials on their website that can give you more information.
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Blue Banshee Leader (Alex Buirch)
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PostPosted: Fri May 03, 2013 9:17 pm    Post subject: Reply with quote

Soraken Bolt wrote:
The smooth cast products dries to a very solid plastic and does not need any additional support. If you are slush casting a piece, once a layer is dried you can add additional layers to get the thickness you want.

I have made a number of one and two part molds with their rubber products and have cast blasters and some pieces I'll be using for my Endor Commando bandolier. I will be slush casting the head piece for my Lobot in the next month or so. There are a number of tutorials on their website that can give you more information.

Ah, thanks. I'll have to look into that.

I have a bucket of rubber from TAP that still has a fair bit of it left, and I think that should be enough to make a mold or two-- I hope. So I think I have that covered, at least. I'll just have to look into that Smooth-On resin.
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Soraken Bolt ()
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PostPosted: Sat May 04, 2013 2:37 am    Post subject: Reply with quote

If you have any questions about the Smooth-On products send me a PM. I'll be happy to help any way I can.
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Blue Banshee Leader (Alex Buirch)
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PostPosted: Sat May 04, 2013 7:30 am    Post subject: Reply with quote

Soraken Bolt wrote:
If you have any questions about the Smooth-On products send me a PM. I'll be happy to help any way I can.

Sure thing. Thanks!
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ywingfighter (Frank)



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PostPosted: Wed May 29, 2013 5:04 pm    Post subject: Reply with quote

Alec,
any news of your project?
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Blue Banshee Leader (Alex Buirch)
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PostPosted: Wed May 29, 2013 11:58 pm    Post subject: Reply with quote

ywingfighter wrote:
Alec,
any news of your project?

Not yet, no. As I mentioned, I probably wont start these until sometime this Summer, which hasn't started for me yet. I still have a few more weeks of college (three, I think?), so I wont really have time before that. When Summer starts I'll have plenty of time to get to work on it.

Though I have done some sort of work on it, mostly that I've been looking at products things like that. I still haven't completely figured out how I'm going to make the mold-- I have the rubber to make it, I'm just not sure how exactly I'm going to do it yet.
I have figured out that the helmet will probably come in two pieces. I'll also include with it the wedge-shaped greeblie that goes on the top and the spark plug-like greeblie that goes on the left side. But because there are two different versions of the helmet (two different sets of greeblies), the others will be separate, so when someone orders a helmet they can choose which set of greeblies they want.
As for the greeblies, for both styles, the sets will come with everything but the wires, computer connector and chin strap. That will also include the microphone head and possibly the bendable arm, but I'm not sure on the arm yet (but the parts for that can be found at most local hobby stores, it's just a piece of black plastic tubing that covers an RC car antenna and a thin copper pipe that's also used for hobbies-- the copper pipe lets it bend).

I'm not sure about the price yet, I'll have to wait and make a couple and see how long it takes me.

On another note, my mother, who has done most of the sewing, is thinking of starting to sell the pilot AN-H-15 cloth caps and the gaiters.
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seba1983 (Sebastiano Buccella)
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PostPosted: Thu Aug 29, 2013 7:08 am    Post subject: Reply with quote

Wonderful idea .... how's the project?
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Blue Banshee Leader (Alex Buirch)
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PostPosted: Thu Aug 29, 2013 9:35 pm    Post subject: Reply with quote

I got... a little behind. Heh. Sorry.

I've been trying to finish my Jedi outfit by the end of a September for a big troop, so most of my time has been spent trying to get that together as quickly as I can. After that I plan to get serious about the helmet. I don't imagine it will take too long to get the helmet going seeing as most of it is already finished, it's just a matter of doing a little more sanding, making a mold, a mother mold, and then casting the thing.
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G'nott sH'urr (David Campbell)
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PostPosted: Tue May 27, 2014 9:35 pm    Post subject: Reply with quote

Alex
where do the B wing helmet production stand?

Im looking to start my build in the fall, and im in the hunting/gathering stage now, primarily doing research and working on my ANH Y wing . Ill finish up the A wing, then move to the B wing.
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PostPosted: Tue May 27, 2014 9:43 pm    Post subject: Reply with quote

Honestly, the helmet is still on the back burner. I'm still not finished with my stupid Jedi outfit which has taken me way longer than I ever thought it would, and there's been some difficulties in life, as well as a number of financial difficulties, so I haven't had a lot of time to do much work on the helmet. I'm still planning to do them (and still trying to figure out how exactly to do them, which is proving to be a real challenge) but I can't say when I'll get the helmet done.
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Outlaw10 (Jeff Harris)
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PostPosted: Tue May 27, 2014 11:06 pm    Post subject: Reply with quote

Hey Alex,
I recently took a couple of mask making class with Anthony Kosar, who won Face Off. I learned a lot of mold making techniques. Let me know if I can help.
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Blue Banshee Leader (Alex Buirch)
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PostPosted: Wed May 28, 2014 5:28 am    Post subject: Reply with quote

Any tips would be appreciated. I'm just pretty stumped as to how to make the helmet seeing as I don't have access to a rotocast machine or a vaccumform (though I'm not sure that would work, anyway, because I'm not sure if a vacuumform would be able to get the little details that the helmet has, primarily the "vents" on the sides).

I'd like to do the helmet in one piece, which would save some hassle later, but making it in two halves might make the actual molding easier. How I'll split it in half, though I have no idea... I don't want to cut the helmet I have in half, and while I could cut the rubber mother mold in half, I'm not sure if that would screw anything up or not.

Other than that, how to make it is another challenge. When I scratch-built my bigger helmet a few years ago and made a mold and cast it I "painted" on layers of resin onto the inside of the rubber mold along with sheets of fiberglass, but the fiberglass made my hands break out something bad so I'd rather like to avoid that (and not to mention it took quite a while to do, painting a layer on letting it dryer, painting another layer, letting it try, rinse and repeat a dozen or so times) but without it I fear that the resin would just run down the mold and collect in bottom...

So yeah, I'm stumped. The chestbox should be a lot easier, it's a much simpler shape-- it's pretty much just a big square. The helmet, though, I have no idea what to do...
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PostPosted: Thu May 29, 2014 12:00 am    Post subject: Reply with quote

This is a good video showing how to make a slush mold: http://www.youtube.com/watch?v=HZEe8gLJrvY
Once the mold is done, you pour small amounts of a quick drying resin into the mold. While it's still a liquid, slush it around so it gets in all the tiny areas. It'll harden into thin layers. Repeat until you get the desired thickness.
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PostPosted: Thu May 29, 2014 5:46 am    Post subject: Reply with quote

Huh, interesting. It sounds like that might just work...

Is that video not supposed to have sound? o:
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PostPosted: Thu May 29, 2014 5:51 am    Post subject: Reply with quote

Here's a video of the casting process:
http://www.youtube.com/watch?v=1Jmh74ti_Rk
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