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Chefs chewbacca build
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chefhawk ()
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PostPosted: Sun Sep 01, 2013 10:36 am    Post subject: Reply with quote

Thanks Todzilla , yeah after reading your woes about the flanges, i payed allot of attention to them.

I have the lollypop sticks ready for this, i had bought them also for stirring the resin.

Once I've separated the mold halves i will do the drilling i think.
Then its time to remove the clay and work out how much silicone to use.
Im going to use Platsil Gel 10. Its a six minute pot life and an hour curing time.
http://mouldlife.co.uk/Platsil-Gel-10/platsil-gel-10.html
Ive ordered an oil pump to use as a syringe.


Very Happy
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Todzilla ()
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PostPosted: Sun Sep 01, 2013 3:33 pm    Post subject: Reply with quote

chefhawk wrote:
Then its time to remove the clay and work out how much silicone to use.

Learn from my woes on this one too! LOL!

So I thought I was being smart because I filled the mold with water sealing it the best I could then I dumped the water out into a measuring bucket. I even measured a bit more. But when time came to inject, I didn't have enough, I was close, but not to my liking (just barely went to the corners of the mouth). I think my miscalculation was that there will be some silicone still in the neck of the gun (and the gun itself) after squeezing the plunger all the way down. The next time I did it I went overkill and had enough for two masks LOL! I never did quite get the amount right Sad but better to have more then not enough.
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chefhawk ()
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PostPosted: Sun Sep 01, 2013 4:17 pm    Post subject: Reply with quote

...now I'm terrified of making an expensive mistake.

I have found this calculator that (hopefully) will help

http://effektmakeren.no/chavant_platsil.html

Basically you weigh the clay and the above calculator works it out for you

The info comes from a clever guy in Norway who goes by the name BlackOrc and the website is called the effects lab

http://www.theeffectslab.com/forums/

Fingers crossed
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Johnny ()
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PostPosted: Tue Sep 03, 2013 6:03 pm    Post subject: Reply with quote

It's looking great Chef! I was on vacation with the family the last couple of weeks but before I left I at least got my fiberglass mold finished (I still need to remove small bits of clay in a soapy bathtub). I'm curious as to what type of clay you used for block out. Did the brush on PVA work well?
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chefhawk ()
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PostPosted: Wed Sep 04, 2013 4:58 pm    Post subject: Reply with quote

Thanks Johnny,

well after doing 5 coats of waxing and two/three coats of pva, I thought the next stage would be ok....wrong!!
The one part of the flange cracked - i thought it was the sound of the two shells separating. Doh!

Then it would't separate at all!!!


Crying or Very sad
Tried everything to hand including some mens products to "split" the two.



Apache chewie

even soaked it in the bath as the pva is water soluble. Still no joy.

I had asked a guy at work to make me some wood wedges...but he forgot, so i had to wait - which was where i thought i would have to start from scratch again.
But today he turned up with the wedges.



Boom!!! it separated ...phew i nearly jumped for joy, but i celebrated with a can of export instead.

Heres the inner shell with clay still attached. (Chavant nsp)


heres the outer shell where the sculpting detail is.
The flange on the left all cracked and floppy



Last edited by chefhawk () on Sun Aug 06, 2017 5:49 pm; edited 1 time in total
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chefhawk ()
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PostPosted: Wed Sep 04, 2013 5:04 pm    Post subject: Reply with quote

Cleaning the clay off the outer shell. You can see the PVA blue underneath



PVA just peeled off, well most of it





and after washing with water and a toothbrush



heres the flange fixed and waiting to cure




I will sand the repair smooth after its fully cured. Then i will put both sections into each other and then drill out the holes for the nuts/bolts/washers.

cheers


Last edited by chefhawk () on Sun Aug 06, 2017 5:53 pm; edited 1 time in total
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Johnny ()
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PostPosted: Thu Sep 05, 2013 2:29 pm    Post subject: Reply with quote

It looks like you dodged a bullet. I was really worried about it when I separated my front and back halves. I remember seeing Todzilla post where his flange fractured and put on an extra layer. I heard a lot of creaks and cracks but was relieved when they separated without incident. Now I am starting the clay block out phase and have to attempt it again. I hope the original flange will have enough strength for yet another separation. Are you planning on injecting soon?
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chefhawk ()
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PostPosted: Thu Sep 05, 2013 6:59 pm    Post subject: Reply with quote

Yeah, i feel very lucky.

The shells are cleaned and holes are drilled for the nuts/ bolts.

So when the pump arrives i can drill a feed hole and then bleed holes.

Im just awaiting the pump from ebay, then it will be injecting time with the silicone.

The shell im going to use as the underskull seems pretty heavy to me at the moment.Making the teeth is going to be fun.

Ive seen a great video on sculpting teeth by Don Lanning.

heres a preview..




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chefhawk ()
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PostPosted: Sun Sep 08, 2013 9:15 pm    Post subject: Reply with quote

So after drilling the holes in the flanges it was time to drill the hole for the "syringe".
I chose the nose area because this was thickest point when i relined with clay




Quick check to see if the syringe fits....obviously this is the outside and the placement will be inside.




Then it was time for the smaller bleed holes to be drilled.



I then marked the holes so it was easier to see.



Plunger/syringe was then hotglued into position and also wedged in place with a cloth



Both sides bolted together and plunger removed for the silicone to go in



Last edited by chefhawk () on Sun Aug 06, 2017 6:01 pm; edited 2 times in total
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chefhawk ()
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PostPosted: Sun Sep 08, 2013 9:32 pm    Post subject: Reply with quote

Im using platsil gel 10 and the working time is 6 mins.



Timer set..


Jug on scale and reset to zero

the acryilic paint I shall add to part A before mixing.



Both jugs were measured with equal amounts



A teaspoon of paint was added to part A




Blobs of clay sitting on the edge ready for the breath holes for when the silicone leaked out.


Then i mixed part A and part B and poured the mix from a height into the syringe, then with some force pushed the plunger down.

I got about half way, the disaster struck and because i was pushing down the nossel snapped off!!



I desperately tried to force the silicone through the breath holes. I was wasting my time.



I almost forgot to block the main hole where the plunger had been!


Then I had to wait an hour to see what could be saved from this mess.

So then I took out all the nuts and bolts and split the mold.

Heres what was facing me... as you can see the little dots at the top, this is where the silicone should of got to.



After peeling it out and putting onto the future under skull, i was felling better




I then cut out the holes necessary



Last edited by chefhawk () on Sun Aug 06, 2017 6:13 pm; edited 1 time in total
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chefhawk ()
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PostPosted: Sun Sep 08, 2013 9:35 pm    Post subject: Reply with quote

I then painted some pros-aide as a base coat for the acrylic.



Some more painting to do, then its onto the next stage


(THIS WAS A MISTAKE, so no updated pics)

Silicone paint is the only way to do this stage.


Last edited by chefhawk () on Sun Aug 06, 2017 6:15 pm; edited 1 time in total
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Johnny ()
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PostPosted: Sun Sep 08, 2013 10:07 pm    Post subject: Reply with quote

It's great that you had just enough to make your mask before catastrophe struck! These projects sure are an emotional roller coaster ride.
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chefhawk ()
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PostPosted: Sun Sep 08, 2013 10:18 pm    Post subject: Reply with quote

it sure is.. but i suppose if it was easy, then there would a lot more woolies.

I've ordered another pump syringe and whilst i will probably use this, i want to try again.




cheers
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Bacca9 ()
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PostPosted: Sun Sep 08, 2013 10:30 pm    Post subject: Reply with quote

Looking great! can't wait to see it with hair!
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ZeroCooL ()
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PostPosted: Mon Sep 09, 2013 6:59 am    Post subject: Reply with quote

This shocked me at first..... then i couldnt un-see it........ what is that in the bottom left of this pic?

Surprised Surprised Surprised Surprised Surprised Surprised

chefhawk wrote:


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