WIP: Foam Hulkbuster for my 7yr old - Lots of Con Pics!

Re: WIP: Foam Hulkbuster for my 7yr old - 10/9 Torso Ready for Paint!

Thanks for all your support! It's been a long build and some late nights, but hopefully my kiddo has the time of his life this Halloween! :)

So, let's get some PAINT on the chest piece!!!!

Here is it (pre-paint) all masked and ready for plasti-dip...
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I have to say, this is the single most complex item I've tried to coat with plasti-dip... seriously, next time I do this type of thing in pieces... cause this sucked. In the end, I did get it coated (3 coats) with plasti-dip.
21440565074_4d3f946baf_z.jpg


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I was a bit bummed that a bubble showed up on the torso (belly) area of the front... However, when it dried, that almost completely went a way.

After Plasti-dip, I hit it with a round of Adhesive Promoter and then was ready to do the auto paint... I decided that since I have a good gold hand-paint, I figured spraying the gold on first was best (then if the Red coat bleed into the gold area I could easily touch it up).

Here's what the gold base color looked like:
21875511738_8bfde8cac1_z.jpg


I then masked that section off and it it with the auto red paint:
21440559144_820f54603e_z.jpg


Here's the final base coats of paint:
21875215700_f2aa427db4_z.jpg


21876496319_367f7a3ceb_z.jpg


Additional gold areas hand-painting...
21440553534_792b9302d6_z.jpg


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In other news, I also painted the belt piece...
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******

And then, finally, I started creating the pieces I'll need to build the framework of the arms!
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Hopefully I can finish up the chest piece painting and most of the arm structure by the end of this weekend. BIG goal... we'll see if it's possible. :rolleyes
 
Re: WIP: Foam Hulkbuster for my 7yr old - 10/10 Painting the chest!

I can't wait to see your son wearing that nice hulk buster.. I just hope he will not smash hulk after wearing it.. Just kidding.. Looking forward for the whole suit.. Excellent job
 
Re: WIP: Foam Hulkbuster for my 7yr old - 10/10 Painting the chest!

I showed this to my 5 year old and now he wants to be Hulk Buster next year, guess I better start now.

At least he gave you more than 90 day notice! :D

****


So, I got a lot done yesterday, but I took less pictures (sorry).

I did the rest of the basic painting of the chest here's the front - I'll have to snap a picture of the back today... forgot that one last evening.
21901155808_e069e1dda9_z.jpg


With that done, I started on the next BIG project... the arms.

As previously discussed, I'm basing this build on the 'blue-prints' of a greatly enlarged papercraft model by Julius Perdana. In that papercraft model the entire 'action figure' of the Hulkbuster has a wonderfully articulated framework that the paper 'body' sits on. Now, most of what I've done so far, doesn't need that structure as I have a KID inside it! But with the arms, I will be using Julius' internal framework.

His arm structure has 6 points of articulation and are designed to be constructed out of cardboard and rolled paper rods. Here is how it looks in his diagrams...
22100042231_b8772a6c04.jpg


Now, I can't expect cardboard and paper rods to support the MUCH heaver foam build I'm working on for these arms, so I've upgraded the materials slightly. The cardboard pieces will be made out of stiff foam board re-enforced with plastic sheets where needed (mostly around the pivots). The rods will be PVC pipe. This should keep the structure light, but more sturdy than just cardboard.

The little plastic rings I'm using for re-enforcement are my least favorite job of this whole project... there are SO many of them and cutting them out with an blade sucks. But they SHOULD help prevent the PVC from tearing through the foam board.
22089053355_6e8e3095be.jpg


I don't have much progress pictures from the first arm. But here is what it looks like finished. I've taped the paper hand on it just so I can check scale with my kiddo in the suit.
22099049591_61b4a1fc7c_z.jpg


After constructing this I had to do the SCARIEST thing on for this build... cut the hole for the PVC shoulder rod that will fit into to the chest unit. Remember I had mounted a piece of 2x6 on each side of the wooden 'box' that the chest was built on, so now that block of wood needed a hole in it so the Shoulder Rod can be inserted and pinned into place (these will be removable for transportation).

This was pretty scary, as I didn't want to damage the nearly done chest piece.
22089053545_606eefcafe.jpg


It worked out and that meant it was time to see how the arm scaling turned out with my kid in the suit... TEST FIT!!!! :popcorn

First we got him into his black leggings and shirt. Then the lower half of the suit (which still needs LOTS of rigging/fitting work done).
22099056061_b195e9f1ea_z.jpg


Then we got the top half on...
22099048951_0f6f623c03_z.jpg


It might be hard to see without the full arms built and the last torso piece I haven't done yet, but here is the way this build is stacking up to the design:
21901744950_bd26986475_z.jpg


*****

More arm-building today... we'll see how fast this goes. We have a local convention next weekend and I'd love to have him ready to ROCK the suit there prior to Halloween. I'll probably have to skip the weathering of the chest and arms, but even if we just have the basic body done, we'll go and let him show it off. :cool
 
Re: WIP: Foam Hulkbuster for my 7yr old - 10/10 Painting the chest!

At least he gave you more than 90 day notice! :D

****


So, I got a lot done yesterday, but I took less pictures (sorry).

I did the rest of the basic painting of the chest here's the front - I'll have to snap a picture of the back today... forgot that one last evening.
https://c2.staticflickr.com/6/5678/21901155808_e069e1dda9_z.jpg

With that done, I started on the next BIG project... the arms.

As previously discussed, I'm basing this build on the 'blue-prints' of a greatly enlarged papercraft model by Julius Perdana. In that papercraft model the entire 'action figure' of the Hulkbuster has a wonderfully articulated framework that the paper 'body' sits on. Now, most of what I've done so far, doesn't need that structure as I have a KID inside it! But with the arms, I will be using Julius' internal framework.

His arm structure has 6 points of articulation and are designed to be constructed out of cardboard and rolled paper rods. Here is how it looks in his diagrams...
https://c1.staticflickr.com/1/653/22100042231_b8772a6c04.jpg

Now, I can't expect cardboard and paper rods to support the MUCH heaver foam build I'm working on for these arms, so I've upgraded the materials slightly. The cardboard pieces will be made out of stiff foam board re-enforced with plastic sheets where needed (mostly around the pivots). The rods will be PVC pipe. This should keep the structure light, but more sturdy than just cardboard.

The little plastic rings I'm using for re-enforcement are my least favorite job of this whole project... there are SO many of them and cutting them out with an blade sucks. But they SHOULD help prevent the PVC from tearing through the foam board.
https://c2.staticflickr.com/6/5818/22089053355_6e8e3095be.jpg

I don't have much progress pictures from the first arm. But here is what it looks like finished. I've taped the paper hand on it just so I can check scale with my kiddo in the suit.
https://c1.staticflickr.com/1/655/22099049591_61b4a1fc7c_z.jpg

After constructing this I had to do the SCARIEST thing on for this build... cut the hole for the PVC shoulder rod that will fit into to the chest unit. Remember I had mounted a piece of 2x6 on each side of the wooden 'box' that the chest was built on, so now that block of wood needed a hole in it so the Shoulder Rod can be inserted and pinned into place (these will be removable for transportation).

This was pretty scary, as I didn't want to damage the nearly done chest piece.
https://c2.staticflickr.com/6/5828/22089053545_606eefcafe.jpg

It worked out and that meant it was time to see how the arm scaling turned out with my kid in the suit... TEST FIT!!!! [emoji14]opcorn

First we got him into his black leggings and shirt. Then the lower half of the suit (which still needs LOTS of rigging/fitting work done).
https://c1.staticflickr.com/1/781/22099056061_b195e9f1ea_z.jpg

Then we got the top half on...
https://c2.staticflickr.com/6/5753/22099048951_0f6f623c03_z.jpg

It might be hard to see without the full arms built and the last torso piece I haven't done yet, but here is the way this build is stacking up to the design:
https://c1.staticflickr.com/1/571/21901744950_bd26986475_z.jpg

*****

More arm-building today... we'll see how fast this goes. We have a local convention next weekend and I'd love to have him ready to ROCK the suit there prior to Halloween. I'll probably have to skip the weathering of the chest and arms, but even if we just have the basic body done, we'll go and let him show it off. :cool
Absolutely fantastic [emoji2] [emoji2] [emoji106]
Yeah, I had the same issue, but this really seems to help! ;)


*********

Last night I did finished up the chest armor detailing...

I finished adding foam details around where the arc reactor will be:
https://c2.staticflickr.com/6/5786/21859260678_4de690206d_z.jpg https://c2.staticflickr.com/6/5788/22047126455_ab2526994c.jpg

I also finished the trim piece for the bottom of the back:
https://c2.staticflickr.com/6/5706/22057075731_9f341e47eb_z.jpg

https://c2.staticflickr.com/6/5780/21426001233_aa0a491c14_z.jpg

And then I created the 'fastener' details on the side of the torso:
https://c2.staticflickr.com/6/5715/22047298105_743370ebd6_z.jpg

It is now ready for masking and the first coats of Plasti-dip!!!!
https://c1.staticflickr.com/1/706/22047122045_872dd64bc8_z.jpg

More updates after the painting has started! :)


Sent from my SM-G900F using Tapatalk
 
Re: WIP: Foam Hulkbuster for my 7yr old - TEST FIT PICS!

Finished up the second arm structure...

21913304859_8ae70e7bf4_z.jpg


and then I built the most helpful thing ever... this WIP would have been SO much easier of I had started off with this in my shop.

I introduce you to my custom-built Hulkbuster Chest piece mount!!!
21479470243_eed70e5d89_n.jpg


Here's what the back looks likes with the arm structures in place...
22100491245_581ff4c5ce.jpg


And then I finished up the arc reactor and some of the other chest detail pieces...
22100228915_c9ded81341_z.jpg


Things I still need to do:

Prior to Fanboy Expo next weekend...
  • Foam Arms
  • Hands
  • Torso connection piece
  • Rigging the legs/cod piece
  • Mounting the helmet

Other things I'll need to finish...
  • Weathering/Detailing the Chest
  • Weathering/Detailing the Cod piece
  • Weathering/Detailing the Arms
  • Weathering/Detailing the Torso connection piece
  • Sleep
 
Re: WIP: Foam Hulkbuster for my 7yr old - TEST FIT PICS!

Thanks for all the kind words! :$

I've been working, but it certainly doesn't seem to going very quickly... That's probably because I'm building BOTH arms at the same time (which obviously doubles the build time).

Here's the arm progress so far. Starting with the foam covering of the arm structure:
21938521429_e965d609c8.jpg


More details...
22125436595_d663f06b4c.jpg


And finally, the large shoulder pieces...
21980295008_da629dd41a.jpg


22178344271_8afcb16a41.jpg


There is only three more build-days until our local convention (Fanboy Expo - Knoxville). :facepalm
 
Re: WIP: Foam Hulkbuster for my 7yr old - TEST FIT PICS!

3Days ?!

I was thinking this was for Halloween

Lots of late nights coming up , Redbull is in the future.

Loving the work

Dad of the year
 
Re: WIP: Foam Hulkbuster for my 7yr old - Arm Progress

This is incredible to look the progress of. I know when I was a kid, my favorite costume was a box made into a Rubik's cube! I'm sure a few cut corners for a 3 day deadline wouldn't be too bad. Then you have until Halloween to give it those last details
 
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