Green Lantern Kyle Rayner Battery Project **12/22/15**
- Thread starter Luuke
- Start date
Re: Green Lantern Kyle Rayner Battery Project 1/14 **MORE PROGRESS PICS**
Aproximately, how much did it cost to get all those parts laser cut, if you don't mind me asking?
I'd love to use this process on a project.
Nick
Aproximately, how much did it cost to get all those parts laser cut, if you don't mind me asking?
I'd love to use this process on a project.
Nick
megazone27
New Member
Re: Green Lantern Kyle Rayner Battery Project 1/14 **MORE PROGRESS PICS**
Seeing your building process is fascinating and inspiring.
Seeing your building process is fascinating and inspiring.
Re: Green Lantern Kyle Rayner Battery Project **1/25 Progress Pics**
After I talked to my machine shop and showed them what I needed for my handle they realized they couldn't bend metal in the way I wanted with the tight tolorances required. So I went down to TAP and picked up some acrylic rod, picked up my heat gun and map torch and went to work. It's a good thing I bought a 6' legnth. I know I was going to learn as I went with this detail. I figured out very quickly what to do and more importantly, what NOT to do. You can see my first two tries didn't go very well but the learning curve was very fast and the third times a charm. Now I just need to sand and file some detail and I"m ready to take it to a local foundry to see about getting cast in aluminum. Looks simple enough but it did take me about an hour or so to get it right.
These last two pics are showing the cut I had to make to the face where the green lense is going in and how the front plates will cover the opening edge.
After I talked to my machine shop and showed them what I needed for my handle they realized they couldn't bend metal in the way I wanted with the tight tolorances required. So I went down to TAP and picked up some acrylic rod, picked up my heat gun and map torch and went to work. It's a good thing I bought a 6' legnth. I know I was going to learn as I went with this detail. I figured out very quickly what to do and more importantly, what NOT to do. You can see my first two tries didn't go very well but the learning curve was very fast and the third times a charm. Now I just need to sand and file some detail and I"m ready to take it to a local foundry to see about getting cast in aluminum. Looks simple enough but it did take me about an hour or so to get it right.
These last two pics are showing the cut I had to make to the face where the green lense is going in and how the front plates will cover the opening edge.
Re: Green Lantern Kyle Rayner Battery Project **1/25 Progress Pics**
Well I dropped the handle off at the foundry yesterday. I'm only having 15 cast in aluminum. They're costing a little more than I really wanna spend but it will be worth it to have metal handles in the castings. They might be ready to pick up on Friday and I can move forward with the rest of the build. I called and got costs on silicone and casting material today. Probably will order that next week.
I've also started to put plans together for a roto-casting machine since these need to be hollow. I was going the do the three ring method but then I saw an episode on How It's Made and saw a different looking rotocaster I'm going to build that I think will work much better.
Because of that, I think I'm going with either the 7 minute or 15 minutes pot life casting material (smoothcast 305 or 310). I can't wait to see how this is going too turn out.
Well I dropped the handle off at the foundry yesterday. I'm only having 15 cast in aluminum. They're costing a little more than I really wanna spend but it will be worth it to have metal handles in the castings. They might be ready to pick up on Friday and I can move forward with the rest of the build. I called and got costs on silicone and casting material today. Probably will order that next week.
I've also started to put plans together for a roto-casting machine since these need to be hollow. I was going the do the three ring method but then I saw an episode on How It's Made and saw a different looking rotocaster I'm going to build that I think will work much better.
Because of that, I think I'm going with either the 7 minute or 15 minutes pot life casting material (smoothcast 305 or 310). I can't wait to see how this is going too turn out.
Re: Green Lantern Kyle Rayner Battery Project **3/14 Back on Track**
Alrighty then. I decided going the metal casting route is not the way I'm going. I took a closer look at the mini battery and noticed the handle is more square with rounded edges than round. So I had new handles laser cut and I'm going to router the edges for a prototype. I'm then taking it to my machine shop to be reproduced in aluminum. The file is already done he just wants to see a physical representation before we get started.
I've also had jigs made so I can drill holes accurately after pieces have been cast.
I haven't started building the rotocasting machine yet. I've been really busy with home projects.
Pics coming later today. But I'm back on the project.
Happy days.
Alrighty then. I decided going the metal casting route is not the way I'm going. I took a closer look at the mini battery and noticed the handle is more square with rounded edges than round. So I had new handles laser cut and I'm going to router the edges for a prototype. I'm then taking it to my machine shop to be reproduced in aluminum. The file is already done he just wants to see a physical representation before we get started.
I've also had jigs made so I can drill holes accurately after pieces have been cast.
I haven't started building the rotocasting machine yet. I've been really busy with home projects.
Pics coming later today. But I'm back on the project.
Happy days.
strengthof10men
Active Member
Re: Green Lantern Kyle Rayner Battery Project **3/14 Back on Track**
i just love how clean and planed out this looks. most of the things i try do do look like an angry drunk with power tools has run around the room in the dark. lol
i just love how clean and planed out this looks. most of the things i try do do look like an angry drunk with power tools has run around the room in the dark. lol
Re: Green Lantern Kyle Rayner Battery Project **3/14 Back on Track**
I know what you mean. I've realized two things over the years that makes a successful project, planning and patience. It makes a world of difference. I'm hoping to have this ready to mold in a few weeks or less. Then comes the fun part, casting, assembly and finishing. I'm excited about completing this project but I have to remember to be patient and not rush it.
I know what you mean. I've realized two things over the years that makes a successful project, planning and patience. It makes a world of difference. I'm hoping to have this ready to mold in a few weeks or less. Then comes the fun part, casting, assembly and finishing. I'm excited about completing this project but I have to remember to be patient and not rush it.
kalissuperman
Active Member
Re: Green Lantern Kyle Rayner Battery Project **3/14 Back on Track**
this piece is fantastic. if you had the space, time and money, with your skills i could actually see a 1:1 central power battery. lol.
this piece is fantastic. if you had the space, time and money, with your skills i could actually see a 1:1 central power battery. lol.
Re: Green Lantern Kyle Rayner Battery Project **3/14 Back on Track**
Ok here are a few more pics of the new handle prototype. I actually made two of these. One I took to my machine shop to show what I want it to look like and the other is going onto the working original. I'm going to get the vector file over to hime today and he said he could get them done in three weeks. That should work out great. Even better, it's gonna be cheapper than to have them cast in metal. CNC is alwys the way to go.
After I got the new laser cut pieces, I rounded the edges on my router:
Then I hand filed the inside corners. You can see the before and after differences:
And here is a primed piece.
Next photos will be the handle attached to the outside brackets and then attaching the complete handle system to the main body.
Stay tooned!
Ok here are a few more pics of the new handle prototype. I actually made two of these. One I took to my machine shop to show what I want it to look like and the other is going onto the working original. I'm going to get the vector file over to hime today and he said he could get them done in three weeks. That should work out great. Even better, it's gonna be cheapper than to have them cast in metal. CNC is alwys the way to go.
After I got the new laser cut pieces, I rounded the edges on my router:
Then I hand filed the inside corners. You can see the before and after differences:
And here is a primed piece.
Next photos will be the handle attached to the outside brackets and then attaching the complete handle system to the main body.
Stay tooned!
Re: Green Lantern Kyle Rayner Battery Project **3/15 Back on Track**
Oh vey. I have been a busy bee. In the last month I've been working feverishly on my house. We just had a new breaker panel put in, new ceiling fan boxes put into the bedrooms, been talking to contractors about wall insulation, ordering custom windows and taking out a sliding glass door, replacing it with an exterior door and walling the rest.
Oh and been working on the battery too.
So I've just about got the handle completed and ready to attach to the main body. The main body is now permenantly attached to the base. I'm gonna now order silicone and resin, finalize my rotocasting plans and get it built.
Pics to come.
Oh vey. I have been a busy bee. In the last month I've been working feverishly on my house. We just had a new breaker panel put in, new ceiling fan boxes put into the bedrooms, been talking to contractors about wall insulation, ordering custom windows and taking out a sliding glass door, replacing it with an exterior door and walling the rest.
Oh and been working on the battery too.
So I've just about got the handle completed and ready to attach to the main body. The main body is now permenantly attached to the base. I'm gonna now order silicone and resin, finalize my rotocasting plans and get it built.
Pics to come.
Re: Green Lantern Kyle Rayner Battery Project **5/2 Ready for Molding**
Sorry for the lack of updates and pics but I have been running myself ragged. Between the house and a couple of other projects things have been moving slowly but surely with the lantern battery.
All of the pieces are ready for molding. YAY!
Now I'm ordering silicone and parts for a rotocasting machine. Pics will come...seriously.
Sorry for the lack of updates and pics but I have been running myself ragged. Between the house and a couple of other projects things have been moving slowly but surely with the lantern battery.
All of the pieces are ready for molding. YAY!
Now I'm ordering silicone and parts for a rotocasting machine. Pics will come...seriously.
nightwing615
New Member
Re: Green Lantern Kyle Rayner Battery Project **5/2 Ready for Molding**
Since Rayner is my favorite GL, I had to check this out. The work you've done so far is superb! I cannot wait to see the final product!!
Since Rayner is my favorite GL, I had to check this out. The work you've done so far is superb! I cannot wait to see the final product!!
Re: Green Lantern Kyle Rayner Battery Project **5/5 Pics of Molding Master**
Hooray Pictures!!!
Yes, I finally got off my buttocks and snapped a few photos.
Here are a couple of pics of the handle attached to the "chicken wing" sides:
And here are a few pics after spraying it with primer and size comarrision with the mini battery. Now if you haven't been following the thread, it looks funny right? Because the front and back pieces the lenses go into are going to be cast up separately. Anywho, here are the pics:
I've got parts on order for the rotocasting machine and I still need to order silicone and resin.
More to come
Hooray Pictures!!!
Yes, I finally got off my buttocks and snapped a few photos.
Here are a couple of pics of the handle attached to the "chicken wing" sides:
And here are a few pics after spraying it with primer and size comarrision with the mini battery. Now if you haven't been following the thread, it looks funny right? Because the front and back pieces the lenses go into are going to be cast up separately. Anywho, here are the pics:
I've got parts on order for the rotocasting machine and I still need to order silicone and resin.
More to come
kalissuperman
Active Member
Re: Green Lantern Kyle Rayner Battery Project **5/5 Pics of Molding Master**
this is insane. one day I also hope to own my own lanterns. that being said, i would love to know if you ever make this item available to others.
Great work. i never fail to be impressed by your talent.
this is insane. one day I also hope to own my own lanterns. that being said, i would love to know if you ever make this item available to others.
Great work. i never fail to be impressed by your talent.
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