Revisiting 'off the shelf' components, the ZF1 is known to use the Estes Bullpup model rocket. Though, it is accurate to use the supplied cardboard tube (images from recent Prop Auctions verify the use of the paper tube), screenshots during the demonstration show a machined body tube with a...
Newly acquired info prompts a new build - more accurate, more detail, and more options. (yes, dart launchers and 'instant replay' sensor included).
First a benchmark of prior versions :
Metal Frame (Full aluminum frame)
Metal parts (derived from screen used prop),
Electronics & Lights (same sent to Adam Savage)
Epoxy Fiberglass shell (molded from production used prop)
Full size replica of Zorg's Mangalore demo weapon with all options deployed. All aspects are being revisited...
If I read it right, you don't want to go through the expense of vac forming.
There are 2 methods that I know of:
1. Form armor out of foam mat and coat with plastic resin.
2. cover body part with thick towel to help insulate and wrap heated plastic (use oven and a wood frame to evenly heat...
Electrical section at Lowes, Home depot, etc; What you're looking for is 'Fish Tape' - used to pull wiring through conduit, but works great when repurposed for props/costumes. 25 feet will put you back about $20.00.
Re: ZK's ZF-1 reasearch/build thread
By request, and following up on the pod paint template post (#232), here are the paint codes that I currently use (note: next build will have a darker gray for #10):