Scratch Built Indiana Jones: Raven Saloon Staff of Ra Headpiece

[zenx13]

Greetings all!

I haven't posted in awhile, busy with life and client projects, but I am caught up and have some time at Christmas for a personal project!

I have been a fan of this prop since seeing "Raiders of the Lost Ark" in 1981 and have always wanted to have one. In the last few years I have been practicing sculpting and am excited to take on this build!

I have chosen to replicate the Raven Saloon Staff of Ra Headpiece - let me know if you have any questions or comments.

Cheers!
/sean

 

[zenx13]

Step One: Reference Materials and Base

I located a number of reference materials and prop dimensions - from there it was transferred to thin MDF as the base of the build.

 

[zenx13]

Step Two: Shaping Base

Using a coping saw I cut out the base of the build.

 

[zenx13]

Step Three: Twisted Wire

Using a drill and two strands of wire I made the twisted wire filigree that runs along the outer edge of the headpiece.

 

[zenx13]

Step Four: Mounting the Twisted Wire

I taped the wire into place and then secured it in about 6 places using CA Glue and Kicker. I followed this by carefully adding PVA glue to the gap between the wire and the base with a paintbrush.

 

[danvader]

Hey Sean, these steps are very inspiring and I can't wait to see what happens next

Scratch-building: the old school, not as convenient as 3D printing, BUT...the best way of building prop !

 

[zenx13]

Hey Sean, these steps are very inspiring and I can't wait to see what happens next

Scratch-building: the old school, not as convenient as 3D printing, BUT...the best way of building prop !

Very kind of you to say - I don't own a 3D printer myself, I still get the most enjoyment out of the process rather than the finished item. The issue I run into is time (lack there of) and find Christmas break to be a chance to make something for myself. Thanks again and stay tuned!

 

[zenx13]

Step 5: Inner Wire

The first set of inner wires were created using Round Nose Pliers - this is something I used to do many times when I was Silversmithing.

 

[zenx13]

Step 6: Character Engraving

To accomplish the look of engraved characters I ripped a thin piece of XPS Foam and traced the characters onto it. There were a number of steps involved:

 

[zenx13]

Step 7: Adhering the Engraved Layer

I coated the wooden base of the medallion with quick drying carpenter's glue then affixed the engraved foam layer (note: I paint the backside of the foam with acrylic paint as it helps to stick faster and stronger). Here it is with the inner wires resting on it - tomorrow I hope to bring the other side up to this point and affix the inner wires.

 

[zenx13]

SIDE NOTE: It isn't all Fame and Glory...

I had one side completed but spent too much attention on getting the head to line up and being adhered well. Wasn't till after it all dried that i noticed it was way off centre. Had to be cut off and will need to be redone - I worked on the other side as I had that ready to go.

Scratch building always has setbacks - you just need to accept that and move on... that is all.

 

[Snow Builder]

I'm enjoying watching your progress, can't wait for the next update.

 

[zenx13]

I'm enjoying watching your progress, can't wait for the next update.

Thanks for the kind words!! I am really hoping to complete this build before the end of Christmas break!

 

[zenx13]

Step 8: Making the Rest of the Wire Embellishments

First I re-created the foam engraving slice and glued it to the base correcting my earlier issue.

Then I used a Jeweler's Ring Mandrill to shape the wire items at the top of the Headpiece and did a dry-fit:

 

[zenx13]

Step 9: Adhering the Wire Embellishments

Using Foam Safe HPD Super Gold + glue I affixed the wire items. HPD Insta-set Accelerator was also used as it doesn't react with the foam.

The last photos shows the full progress with both sides finished to this point.

 

[zenx13]

Step 10: Shopping Trip!!

I raided Michaels and snagged some great items for the necklace and the gem eyes.

Then I went to a awesome local coin shoppe: Calgary Coin to locate some Asian Cash Coins and found a treasure trove of them! They range in age (you can't determine the age) and may be as old as over 100 years.

I bought a number to have for stock but if anyone would like one send me a message!

And this is the mock up - One of the turquoise stones will need to be painted red but I am really happy with how it looks so far!

 

[zenx13]

Step 11: The Eye

I drilled a pilot hole in the eye area of the headpiece then cut the area out with a coping saw. I test fit one of the gems - looks great!

 

[zenx13]

Step 12: Slot for the Staff Connection

This was a part of the project that I was not looking forward to. I am not sure if I will ever make the staff connector - I will probably display the headpiece on Marion's necklace. Regardless the Headpiece requires a slot in it to be accurate.

I did a test on a spare piece of MDF with a drill but that failed. I tried to remove the material with an exacto knife but the results were so/so.

In the end I decided to cut the area out of the Headpiece and reconstruct the slotted area out of tongue depressors. I am pretty pleased with the results and the item will be accurate and prepared if I want to make the staff connector.

 

[zenx13]

Step 13: Prep for Primer

On occasion spray primer can melt foam but the metal items require the primer to make sure the paint will stick. To be safe I coated the pink foam in Mod Podge - this works as a barrier and allows me to prime the whole item. I hope to do that in the next few days.

The last photo is where the project is at now.

 

[zenx13]

Step 14: Primer

A quick coat of primer to protect the metal and provide adheasion.