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  1. joberg's Avatar
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    Sep 2013
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    2 Weeks Ago  May 11, 2017, 7:57 AM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #51

    Wow, the amount of work involved is staggering when you pose and think of it...it's a good thing that you have lots of little hands helping you. Keep up the great work, it's going to be the bomb when finished!!
  2. RPF Premium Member Ein's Avatar
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    Oct 2011
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    2 Weeks Ago  May 11, 2017, 10:36 AM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #52

    I'm going to be the mook that asks for specifics about the fiberglassing process you're doing to make these molds. What's the clay you're using to build the walls? Can you go into more detail about the materials you're using, and what you're casting the finished parts with?

    Power armor like this was one of those projects I wanted to do and have been thinking about for the last year while I work on other things... I have to say, seeing half a dozen+ people work on this project is driving home how much labor's involved. Not sure I could tackle this if I wanted to, based on what I'm seeing.
  3. RPF Premium Member karmajay's Avatar
    Member Since
    Jan 2014
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    Wendell, NC
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    2 Weeks Ago  May 11, 2017, 10:40 AM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #53

    Poor poor Thorssoli. Any money he makes on these projects just goes to storage space for all those molds!
  4. RPF Premium Member thorssoli's Avatar
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    Dec 2005
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    Petaluma
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    4 Days Ago  May 22, 2017, 6:13 PM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #54

    karmajay said: View Post
    Poor poor Thorssoli. Any money he makes on these projects just goes to storage space for all those molds!
    This one's not a money making project. Maybe someone else will want one sooner or later, but for now it's just a thing to keep me busy in between paying gigs. The storage space is no joke. I'm thinking I'll have to purge a couple of shelves and get rid of a lot of things in order to find space for these babies. Right now, my shop's getting a bit cluttered:


    joberg said: View Post
    Wow, the amount of work involved is staggering when you pose and think of it...it's a good thing that you have lots of little hands helping you. Keep up the great work, it's going to be the bomb when finished!!
    I try not to pause to think of the amount of hours in this thing. It'd end up making me upset. That said, it's been fun hanging out with a few friends when they get a chance to come by and lend a hand.

    Ein said: View Post
    I'm going to be the mook that asks for specifics about the fiberglassing process you're doing to make these molds. What's the clay you're using to build the walls? Can you go into more detail about the materials you're using, and what you're casting the finished parts with?

    Power armor like this was one of those projects I wanted to do and have been thinking about for the last year while I work on other things... I have to say, seeing half a dozen+ people work on this project is driving home how much labor's involved. Not sure I could tackle this if I wanted to, based on what I'm seeing.
    The clay I'm using for the mold walls is a plastilene oil-based clay. Soft grade Chavant NSP works just fine. You can get it here: http://amzn.to/2rK3xpg

    I'm using orange tooling gelcoat and black regular gelcoat from whatever supplier offers the lowest price when I'm buying. That stuff seems pretty consistent. The laminating resin is polyester bond coat from TAP Plastics. The glass mat is 3/4 ounce mat, also from TAP. I use the same resin and mat for both the molds and the final parts. The molds get at least three layers of mat. Usually more like four. The parts are usually two layers with a third around the edges for reinforcement. At some point, I'll be editing together a few Youtube videos about this project that will describe the process in greater detail. In the meantime, you can check out more of the same sort of work in this other project I did where I explain molding (LINK) and laying up parts (LINK) in fiberglass.

    Labor-wise, it wouldn't be so bad if it weren't for the fact that I decided to pick up the pace here at the end. If I wasn't in a hurry, I'd happily do it all myself over the next few months.

    On that front, it's time for an update.

    It's been about a week since my last post. In that time, I finished the four-part mold for the back as well as a five-part mold for the chest. Here you can see both of them (and the heel mold) ready for gelcoat and fiberglass:


    At the same time, Lewis put the finishing touches on the shins:


    And the finger parts:


    While he was working on those, I also made a 7-part mold for each of the shoulders:


    The toe mold was finished with one section made of silicone so I could capture the more delicate ridge details on the front end:


    The same thing was done for the lug details on the front of both shoulders:


    On the subject of silicone, I went ahead and molded the helmet:


    With all of the rushing, I neglected to get photos along the way. Still, the mold got done and the first cast came out okay:


    I also went ahead and boxed up the finger pieces:


    Each of those boxes will become a two-part rubber block mold when I get a chance to separate them. They're just some of I don't know how many small molds I've got scattered around the shop for this project right now:


    But the bulk of my time this past week has been spent laying up fiberglass. Here I am making the very last section of the very last fiberglass mold for this project:


    Sadly, I wasn't able to get the last five parts laid up in the molds in time to have this guy walking around at the Bay Area Maker Faire this past weekend. I came really close (there's already black gelcoat in those last five molds) but it'll be tomorrow or Wednesday by the time I've had a chance to get a bit of rest and finish up that last bit of glass work. Still, for the folks that were at the Maker Faire, I had plenty of other things to show off:






    So, after deciding to postpone the rest of the T-60 project for a couple of days, loading up my whole display worth of props and two truckloads worth of costumes, and three days on my feet answering questions and telling people about prop making, I've decided I need a day off so I can see straight again:


    For now, here's where the project stands:


    It's worth noting that all of the orange parts will be grey in a couple of days. Then I just need to make a prototype for the tanks on the back, design the rigging for the finger articulation, and sculpt all of the rubber bits.

    Piece of cake.
  5. Member Since
    Jul 2015
    From
    Alabama
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    80
    4 Days Ago  May 22, 2017, 8:21 PM - Thorssoli's T-60 Power Armor Build from Fallout 4 #55

    Have you considered using something like the CO2 tanks made for paintball?


    Sent from my iPhone using Tapatalk
  6. joberg's Avatar
    Member Since
    Sep 2013
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    3,611
    3 Days Ago  May 23, 2017, 11:51 AM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #56

    Well, that display of yours really rock ...and back at work; I admire your stamina. it's quite the project for sure
  7. Member Since
    May 2017
    Messages
    1
    3 Days Ago  May 23, 2017, 5:04 PM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #57

    That is really impressive! I love how a project of this scale is "one to keep you busy between paying gigs".

    I'll definitely be keeping an eye here. And someday when I have a few Gs kicking around, may be buying one.
  8. RPF Premium Member thorssoli's Avatar
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    Petaluma
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    10 Hours Ago  May 26, 2017, 11:05 AM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #58

    Wimismith said: View Post
    Have you considered using something like the CO2 tanks made for paintball?
    They're too narrow. I need tanks that are about 4.5" in diameter. They also need grooves to fit the tie-down straps or bands that are visible in the artwork. That, and the neck at the bottom where the hose attaches is unusual as well. I'll probably end up just turning something down on a lathe.

    joberg said: View Post
    Well, that display of yours really rock ...and back at work; I admire your stamina. it's quite the project for sure
    I'm pretty proud of the display. I'll be putting up a similar thing at the Santa Rosa Toy Con in September of this year. It's kinda the only way I get a chance to go to these sorts of things.

    HalifaxReplicas said: View Post
    That is really impressive! I love how a project of this scale is "one to keep you busy between paying gigs".
    The really sick part is that this isn't the only project I've got going in that category. It just happens to be the one that's captured my interest for the moment.

    UPDATE!

    The finger molds are done:


    These are what I call "smoosh molds." To make the hollow castings, I start by filling each cavity about halfway:


    Then I insert the silicone plugs which displace the liquid resin and shape the insides of each piece:


    A bit of overflow at the top means the molds are full enough and there won't be any bubbles at the top edges of the parts:


    Because I'm terrible at documentation lately, I don't have a pic of the first set of parts cast. But you can see a few of them in the top left corner of that last pic.

    In other news, I've pulled the last five fiberglass parts for this project. The biggest ones were the shins and the smallest one was an upper arm, pictured here:


    I also pulled the back of the thighs:


    They look awkward as hell, but the front portion is what will make it possible for a normal-sized person to walk:


    Still, this guy's legs are HUGE:


    While all of that has been going on, I've also cast some of the detail bits for the helmet:




    I've still got a handful of really small molds to pour (including the clear lens for the headlamp) and then this thing will be ready for some final trimming and painting.

    Stay tuned...
  9. andsuor's Avatar
    Member Since
    Jul 2014
    From
    Trondheim, Norway
    Messages
    16
    9 Hours Ago  May 26, 2017, 11:52 AM - Re: Thorssoli's T-60 Power Armor Build from Fallout 4 #59

    I love seeing these updates. Great work, as always! Can't wait to see it finished.

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