A new Chewie in Germany

Nostradamus · Aug 17, 2022

So, my new Wookee feet are done. I've followed AS's example more closely this time. So I didn't take another mount/binding for the snowboard boots.
I first glued the boots to the foot with hot glue. Then fill in the gaps.
Then everything was neatly glued with duct tape. The foot also has less weight. About 1 kg less than the previous model. And it's comfortable too. Walking is great too

Nostradamus · Aug 17, 2022

As a small additional idea, I built myself a walking stick. The forest gave me a good one. After a good amount of rasping and grinding, the helmet could be processed. A fallen trooper must serve for it.

An idea from the forum and based on a scene, I think Clone Wars. Or rebels?
First demolished the helmet a bit and then put it on the skewer. I don't think it turned out that bad.

Sorry troopers.

Nostradamus · Nov 25, 2022

Meine 3 verschiedenen Wookieefüße im Test
My 3 different Wookiee feet in the test

Nostradamus · Jan 12, 2023

The test showed it. While I was very happy with the direct attached boot version, the WalkTall version is a tad hotter. The connection with the medical supports cannot be beat. So I'll focus on that and continue to build on it.
First I take care of the hair that still needs to be attached. Meanwhile, I wrote to other Wookiee brothers and got me some tips.
I first provided the WalkTall with M5 holes. First I will cut out a PVC plate as the base sole and attach it to the WalkTall with impact sleeves.
I also ordered EVA in 20mm, which I then glue to the bottom as a sole and as the last layer a thin rubber sole - because of the slipping.

Nostradamus · Jan 12, 2023

The toes, yes, that was such a problem with each of my versions. I have the silicone toes from the first version and can attach them to the new ones - if only I knew how. However, I have another idea. I am currently printing a set of toes which are of course lighter than the silicone ones. We'll see how it looks when they're done.

I still don't have the right idea for the shin. I have a few, but none of them have convinced me so far.

Nostradamus · Jan 17, 2023

The new Wookiee feet. Why? Because I just want more stability and security. This variant is very promising and I think these will become my main feet.
I have already connected the WalkTall and the medical splint with screws. The first walking tests with and without boots were very good.
So I've now ordered the next parts.
I drilled M5 holes in the edge so that cylinder head screws can go through. Below is a PVC mat which I will attach with impact sleeves.
EVA is used as the sole underneath. This is special for cosplay, etc. Has fixed properties (depends on which one you take) and is easy to process.
Of course, there are also special glues for this. So if everything works out, I'll pack 2 soles with 20mm each underneath. I have to test that, maybe 20mm will be enough. More sole means more smooth gait. However, higher again.
As soon as I have the first layer on I will test it and then decide.
EVA is also used to support the shin. I have an idea how I can attach it, but I have to measure it more precisely first.
Of course I can slowly pick out the Wookiee hair again. Because you have to turn it again.

So, the right toes are printed and I'm really excited about it. Look very chic. The shape is also great, so that not too much has to be cut. At least I hope so.

Nostradamus · Jan 17, 2023

The left toes are also ready, the PVC has arrived and we can start.
First cut off the sole and mark the holes. Then these holes are slightly enlarged and the M5 drive-in nuts are used. After so much back and forth it finally fits.
Then I used a heat gun to heat the PVC and bend it a bit to fit the WalkTall. As a result, the marked and already drilled holes no longer fit, which is why I have to improvise something.
Then the overhangs are removed with the band saw and the sole is now actually finished.
I was so happy about the low weight of the Wookiee feet, which has now settled.
10mm PVC. That's a lot more weight than I thought. Ok, so it should be stable. Nevertheless, I am considering replacing them with 5mm. But, first I'll finish this one.
And then I have to think about how to attach the toes and in what way. They shouldn't be too high and then float.

Nostradamus · Jan 25, 2023

So, the second sole cut out and prepared up to the drive-in nuts. Then I wanted to color the WalkTall. Cover with some cling film and off you go.
First primer and after it was dry with black afterwards.
Did it work out? Of course not.
Well, it's probably not that easy to color a plastic bucket. The paint just peels off with the primer. This is one of those moments again... maybe I should have just used black duct tape. That always works.
My EVA has also arrived and I can now get on with the sole.
I weighed my foot too. So he has a proud 4kg.

Nostradamus · Jan 25, 2023

Next screwed the PVC panels together and then cut the EVA to size. The EVA can also be shaped when heated. But now I'm wondering if the drive-in nuts don't take up too much space to glue the EVA to the PVC? It gives way, yes. But, is that enough to create a secure connection?

I sanded and primed everything again. Waited longer this time to let it dry. And then again with black paint over it. It held up this time. I guess I was too hasty the first time.
I cut out another sole - a little longer. I somehow forgot about the toes. And now the same question is again: how to fasten the damn parts???

Nostradamus · Jan 25, 2023

Here and there some of the paint still seems to come off, but that doesn't matter.
The toes, how to attach? Thanks to the Facebook group I got some ideas. After some thought, I decided on my first idea. A metal punched tape. This is stable and yet slightly flexible. So I cut out the toes a bit, drilled a hole and used an M4 bolt and locknut to attach the perforated strap to it. The first test is quite promising.

Nostradamus · Jan 25, 2023

Then I got busy with the EVA. That typical bump on the shin - you know what I mean. I've also found other ideas on the forums and Facebook, and this one appeals to me the most so far. Even if I don't know how best to attach it or how to put it on later.
But with the hair on it doesn't look bad.

Nostradamus · Jan 26, 2023

The shin is really a bit of a challenge. I had seen this solution with EVA on other Wookiees. But somehow I can't do it. Cutting out the EVA is easy, attaching it is something else.

While I'm thinking, I tinker with the toes. metal perforated tape. Stable and yet flexible. A piece at the top to keep the toes on the WalkTall, a longer version at the bottom and once through the entire foot ensures it stays in place. However, it is then no longer possible to unsubscribe. Just break it.
Another Wookiee sent me another idea about the shin. I'll just test that next week.

Nostradamus · Feb 15, 2023

The new shape for the toes is ready and the second one is already printing. This time I fiddled around and created a negative form from the file for the toes and printed it out. A nice 65 hours went on it. per piece
I bought liquid foam to then create my toes. If it works as expected.

Meanwhile I took care of the shin. A few tips from the Facebook group were interesting. I had a few options but decided to attach the EVA with screws. And in such a way that you can easily tilt it to put the shoe on better. A strap to fix at the top and that should have been it.
As soon as everything fits, I can take care of the new toes.

Nostradamus · Feb 20, 2023

First real test of the modification on the Wookiee feet today. I only finished one foot - the left one - to see if I had to change anything.
I have to admit, putting on the costume alone is more than exhausting. I can't do it right on my own. The fat belly is also not helpful.
The hardest part is putting on your feet and tightening all the straps with all that damn hair flying around.
But with a little help it worked and I was able to test it. The shin idea works, the bump is gone. And the trouser leg fits well over it, so that's done too. And the hair I already have for my feet also fits with these. So I'm actually done with it.

Now come the toes. I measured with water. Almost 2 liters fit into the negative mold. I prepared 2 boards to shoot the mold, each including 2 holes as pressure equalization for the foam. I bought liquid foam and am now preparing everything to pour the mold. If all goes well, I'll have my printed toes in foam, which is a lot lighter and more flexible. The painting comes after that.

In any case, I have to think about how I can put the costume on by myself. Because that's how I'm always dependent on someone.

Nostradamus · Feb 22, 2023

14. 22-02-23

An exciting and then disappointing moment.
Yesterday I filled out the form with the flex foam and opened the form today.

One was difficult to get out, but it worked. And the result is also very good.

Then the second came. Unfortunately it wasn't good. Even though I used plenty of release agent, the mold was so stuck that it eventually broke off. That was the moment to get extremely upset and then almost cry.
I'll have a look at it tomorrow and see if I can connect it to my feet well or not.

Nostradamus · Feb 27, 2023

I had tried to color the defective part with acrylic paint. As you can see, with little success. After all, tinting paint was the panacea. Applied generously with a brush, the result is already very good. After drying comes a second coat and that should then fit. Then some black here and there and done.

Meanwhile I got the second try of the toes out of shape. You can tell immediately that I used even more of the release agent this time, because the part came out of the mold quite easily. Unfortunately, the strap slipped a bit, but that's bearable.

Now you can start adjusting. I'm still deciding which is better. The foam is lighter and more flexible.
But if I want to use the printed toes, I have to use a different type of attachment. And simply converting and changing is not possible.
Difficult, difficult.

Cmdr.Kerner · Feb 27, 2023

Nostradamus said:
I had tried to color the defective part with acrylic paint. As you can see, with little success. After all, tinting paint was the panacea. Applied generously with a brush, the result is already very good. After drying comes a second coat and that should then fit. Then some black here and there and done.

Meanwhile I got the second try of the toes out of shape. You can tell immediately that I used even more of the release agent this time, because the part came out of the mold quite easily. Unfortunately, the strap slipped a bit, but that's bearable.

Now you can start adjusting. I'm still deciding which is better. The foam is lighter and more flexible.
But if I want to use the printed toes, I have to use a different type of attachment. And simply converting and changing is not possible.
Difficult, difficult.

Hi Dejan,
I'm really looking forward to see your finished feet from the Wookiee project. Maybe at the Maker Faire in Hannover?

Nostradamus · Mar 1, 2023

17. 28-02-23

The second attempt of the foam toes was successful this time. This time I had so much release agent inside that the part almost fell out by itself. The strap slipped a bit, but I was able to fix that.
Then I cut the part and adapted it to the foot.

Once I was happy with that, it was time to color it.
The first toes have had the first 24 hours and are now getting the second layer. While the second toes are now getting their first coat of paint.

I'm very impressed with it so far and I'm starting to think about the best way to attach it.
I connected the velcro strap to it because I thought it would be a good idea. Now that the time has come, I have my doubts as to whether this is the right way.

Nostradamus · Apr 14, 2023

Today I gave the toes the second coat of paint. These have slightly larger pores than the first. Whether the mixture didn't quite fit or whether there was too much release agent, I can't say. But, with a lot of paint it works.

After that I took care of my existing Wookiee feet again. I don't know if I'll get my new ones ready in time, which is why I've made my previous ones again. Again, the problem is with the shin. I'll try it with a PVC cloth. It's light and easy to fold. Maybe I just made it too short? It's just below the knee. I liked a walking test with the idea. I can walk well in these feet, although I think the new ones would be better.
Walk as quickly and naturally as some other Wookies, but I can't do it. Maybe because of the height, or maybe I didn't do something right. Anyway, I walk like an "old" Wookiee.

Nostradamus · Apr 19, 2023

New idea. Cut EVA to size and attach with duct tape.
I had to take care of my Wookiee Feet V2 quickly, because a photo shoot with the Star Wars Dinner Hamburg was coming up and I wanted to be done with it. This option also worked great and a small walking test was successful. It can stay that way.