Darth Vader shins from scratch

P3laton3 · Apr 29, 2017

Hi all, I posted a similar topic on another board looking for info but I wanted start my first one on the RPF showing my work in progress too.
I started this build from a pep file and the first attempt was slightly oversized so I started all over and made a closer size to the originals.
Here some pics taken during this step

Then I made a "better" one

The previous one

And the one after

Then I reinforced the whole to don't loose the shape during the resin and bondo coats

And first layer of urethane resin, I used this one as it was too cold outside to allow the polyester to cure properly

And a second layer with black pigment

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P3laton3 · Apr 29, 2017

I noticed anyway that the pep file is a bit off if compared to the real bits, too flawed at the base and the diamond shape at the top is a bit too narrow. Also the curvature on the calfs is different from one size to the other.
So I had to change my plan and I thought to make a symmetrical one as base for a proper sculpt.
Working with resin and bondo turned out to be a bit too much time consuming and quite hard when you need to change shapes and curves.
In the meantime I wanted a good base for my first one off mold.
Here few other steps with bondo and polyester resin to reinforce the walls and make it more symmetrical

So I thought to make a symmetrical shin

Then a layer of fiberglass at the back for extra support

And a deep session of sanding to start fixing the inaccuracies

To build extra walls I made two supports at the top and at the bottom and filled with a mix of resin and strands of fiberglass

And a bit of extra bondo to smooth the curvature in the the ankle area

Here once removed the carton board with extended walls at the back and extra thickness at the bottom waiting to be sanded

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P3laton3 · Apr 29, 2017

Other little progresses
I made my own Spaghetti gauge to copy the curvature from one side to the other

Which turned out to be extremely useful

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P3laton3 · Apr 29, 2017

After the last sanding session

P3laton3 · Apr 29, 2017

From my researches it seems that there are many versions around some cast from screen used ones other fan made.
I am aware of the two different sizes between the right and the left one which is around 17 inches and I know for sure that the model hasn't changed across the Original Trilogy.
I have been studying tens of pics and I noticed some discrepancies between the original pictures, the ones used for the tours and the ones that should be accurate.
I summed up few shapes and curves from the shins that I have seen around.

Here below on the knee pad I noticed different edges from different makers from sharp to fully rounded

On this other drawing the same area but on the side lines that define the diamond shape itself

This time on the top edge that runs from the back to the knee pad

Here a comparison for some thoughts the first one is an original picture

The second one is cast from an original stunt one

Now I am a bit more puzzled about my sculpt

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P3laton3 · Apr 29, 2017

This is the last for tonight I promise...
Here other few mock up I made to work out the measurements on its wider point and a comparison with my wip
Here side to side two original pictures

Here I made the left one symmetrical for fun

And here a comparison with my work in progress

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Bengrim09 · May 3, 2017

I love seeing scratch builds, lots of ups and downs, success and failures but in the end very rewarding keep it up I've subscribed :thumbsup
you work at ILM London ? Give Steven Lovell in layout a knock he's my step son ( lovely chap )

P3laton3 · May 4, 2017

Really? Indeed he's a great guy he's just been moved in our previous room in the new building along with his dept.

By the way I moved some steps forward on my project, I made a quick mold with plaster bandages and once well waxed I poured Plaster in the mold to have a positive copy of my initial efforts.
The resins and all that car filler was just too messy and too stinky to allow me to work at closed doors.
Here some pics of the latest progresses:

Here I filled the shin with some foam

filled the gaps with clay

half mold

the overlapping side

and ready for the plaster

quite thick as I needed to carve a bit in my original shape

there you go a good start for a proper sculpting

P3laton3 · May 4, 2017

Bengrim09 · May 4, 2017

Nice work
can't wait to see more

P3laton3 · May 4, 2017

P3laton3 · May 4, 2017

Is there anyone here that can pass me some info about the shins? I am still puzzled about the true measures and proportions..

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Friendly flyer · May 4, 2017

Very impressive work!

Bengrim09 · May 5, 2017

Isn't it all depending on your size if your building for yourself to wear trooping then it needs to fit you as long as you have the correct details size only matters to you
but if your building a screen accurate for a display somebody should be able to point you in the right direction for members names and research
i hope you get the help you need

P3laton3 · May 8, 2017

Small updates on the main shape

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P3laton3 · May 8, 2017

Bengrim09 said:
Isn't it all depending on your size if your building for yourself to wear trooping then it needs to fit you as long as you have the correct details size only matters to you
but if your building a screen accurate for a display somebody should be able to point you in the right direction for members names and research
i hope you get the help you need

The plan was to sculpt them for myself without caring too much about screen accuracy but as I started doing some deeper researches I got fascinated by the inaccuracies. Is like when you like to drawing or taking pictures of people for portrait them after a while the research for the absolute canonical beauty is replace by what likes you and the details that make a person or an object unique. Also I have found that the measures will fit me so I changed mind and now I am trying to sculpt them as close as possible to the screen used ones.
I received some good references that enlightened me about some bits here and there will see where I'll go with those.

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P3laton3 · May 8, 2017

Still a long way. Can't wait to the next session

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P3laton3 · May 29, 2017

Here after a couple of days sanding and filling and adding volume and reshaping.
As I said the initial plan was to sculpt only one symmetrical shin and then cast it.
Then I moved on a more accurate version based on the original seen on the prop store a while ago.
I like the asymmetrical shape on each of them but since my shins are pretty much the same lenght I won't sculpt the right one 1inch longer otherwise they won't look right once on me.
Here after Friday night effort

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P3laton3 · May 29, 2017

Sat it's been sanding and filling again

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P3laton3 · May 29, 2017

Sunday again...

Still lot to come but I am feeling very confident now that I am on the right path.
Thanks to the couple of guys that sent me very good reference pictures of the originals and some tips about sculpting the master

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Darth Vader shins from scratch

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