ABC Lifesize head from scratch...

Discussion in 'Replica Props' started by SiR-ROUND, Jan 20, 2006.

  1. SiR-ROUND

    SiR-ROUND Sr Member

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    This is copied from an original thread in the Robocop Archive forum.

    But I guess it belongs here as well. I'm starting off using cardboard to see if it can be done. If I succeed I'll go for Triplex (plywood you call it?) and maybe balsa.

    Njoy.

    A little story:

    I've been wanting a lifesize ABC head for a long time. I actually just found a kit taken from the moviemolds on Golden Armour. For a good price also. But... My collecting craze is slowly settleling again, pfew. It's not worth it to make huge debts ofcourse. I had to draw the line somewhere.
    So my idea was to actually start building one from scratch. I was always planning on using wood as a start for the prototype. Dave's work on the Robosuit got me really enthousiastic again. I know I have a Lawgiver paperproject waiting, but dudes, I get bored easily and tent not to finish stuff (rather nasty habit). So I decided to really start creating, that just might keep me going. Also, if I make one myself I won't think twice about making molds for reproduction and even sales. I wouldn't recast somebody else's kit. I have plans for making cheap and easy casts, but that's TS (Top Secret) and xperimental.

    Anyway, I started from paper and cardboard, beginning with the easy part:

    The lower Jaw.

    Cardboard? You said wood, you dumb @#$%. I know, but it's easier to adjust paper and carboard and it's only a head not a full robot. This way I can sticky tape parts and remove and adjust them again. The 3 foot rule actually works pretty good I think, but it is pretty tough this propmaking.

    I have some good pictures of the kit and ofcourse alot of moviepics. Images from the movie however aren't that clear because the ABC was wisely kept in the dark for most of the time. The other thing I have to work from is very handy for the initial measurements: an original Tsukuda 1/9th scale ABC model kit. Although the kit is a bit exaggerated, especially the jaw. The good thing is however, that the adges are sharp and pretty symmetrical. That's not the case with the kit and maybe even the real movieprop. I'm trying to make one as if it was really factory assembled in large numbers. You can always dent and damage afterwards.

    On to some pics:

    The Tsukuda head. I started of with measuring this one. Because it's little there's more room for error. But to get an initial idea of the size (multiply by 9) it's quite handy.

    [​IMG]

    You can see that the chin is a lot longer on the model than on the real thing. The whole model is not as 'bulky'.

    [​IMG] [​IMG]

    But the Tsukuda is very detailed.

    [​IMG]

    The first sketches. The modeljaw on paper in full size with adjustments using the 3 foot rule in the 2D domain.

    [​IMG]

    I made two jawparts from paper because at first I thought of glueing these on the carboard but there was no need to, so one paperpart to many.

    [​IMG]

    The side pieces and the chin + the first bottom attempt.
    I had to make the bottom wider.

    [​IMG]

    Now I can really compare the jaw to the kit images.

    [​IMG]

    Adjustments...

    [​IMG]

    The ABC has a 'slant' in it's 'lips' to make it look more nasty.

    [​IMG]

    Added the back for support and was happy with the chin so taped them on the outside also. Sorry for the bad focus.

    [​IMG]

    Another angle.

    [​IMG]

    Quite pleased. The backpart of the jaw is to long, a leftover from the modeljaw, I have to 3ft my way to a more accurate size and feel.

    [​IMG]

    Now, the jaw is the easy part ofcourse. The round edges on the head and the eyecavities would be impossible to make from cardboard. The idea is to make the head as good as possible with cardboard and paper to see if the proportions are right. With wood and putty the final round edges shouldn't be a problem. Well I had fun so far, hope yall enjoy it too.
     
    ONEYE likes this.
  2. SiR-ROUND

    SiR-ROUND Sr Member

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    A bit hard to see but the back of the jaw already has some pencilmarks for it's proper size. Because of perspective the jaw looks too big for the head and it could be but...

    [​IMG]

    I enlarged the photo this time for the head, instead of measuring and drawing a fresh one like I did with the jaw. I already corrected some minor parts from the model onto the the fullsize. The nose for instance.

    [​IMG]

    The head itself will be a lot of work making out of wood. Ofcourse there's always putty and sanding so it should work out in the end.

    I'm off now to make some cardboard 3D version creations from the upper pics.
     
    ONEYE likes this.
  3. SiR-ROUND

    SiR-ROUND Sr Member

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    Yesterday's little progress...

    The back of the head is added. It's difficult to 'judge' if the size is right, looking @ just the 'skull'.
    The whole time I felt like it was to long.
    But I got used to it and I guess that it actually is longer than I can see from any pictures.
    They all have an angle and the back of the head is rounded so that makes it harder.

    [​IMG]

    Again with jaw. Still looks like the head is too small eh?

    [​IMG]

    Cardboard cutting. Man, I used thick an tough cardboard for the center headpieces. It took me ages to get through.
    I have to do one more of these.

    [​IMG]

    So what ya think of the headsize now compadre? Doesn't look that small now it's held up against the side of the jaw.
    Xqq me for the dangling camerastrap in the lower right...

    :mrgreen:

    [​IMG]
     
  4. SiR-ROUND

    SiR-ROUND Sr Member

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    Well, starting to use glue... All this waiting for it to dry makes me post some more pics. :mrgreen:

    Presse papier... Needed some weight.

    [​IMG]

    What's he doing now?

    [​IMG]

    SANDWICH... Found my clamps.

    [​IMG]

    Get the idea now?
    I decided to start of with the nose size and built my way to the sides.

    [​IMG]

    And this should make it even clearer. Upper jaw.

    [​IMG]

    Upper jaw slanted...

    [​IMG]

    MJ eat ur heart out, this is some whiteass nosejob right here.

    [​IMG]

    It's a one piece nose. I'm getting the hang of it.

    [​IMG]

    Well, the nose should be dry enough to put on now.
    And then... Wait for it to dry again.
     
  5. SiR-ROUND

    SiR-ROUND Sr Member

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    Every good nosejob needs bandage...

    [​IMG]

    Did someone say 'Easter Island'?

    [​IMG]

    Time for dinner, in the left corner... Healing from surgery...

    [​IMG]

    Upper jaw works...

    [​IMG]

    Oh yeah...

    [​IMG]

    Time to cut op the old template. I now think in 2D slices.

    [​IMG]

    Here ya go.

    [​IMG]

    Compared the upper jaw size and width of the head to the upper jaw on my creation.
    Did the math and came up with another stunning construction... ;)

    [​IMG]

    Need spacers again.

    [​IMG]

    Glueing them and on top a not so light bottle of Coke Light.

    [​IMG]
     
  6. SiR-ROUND

    SiR-ROUND Sr Member

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    Aha.

    [​IMG]

    What this room needs is...

    Symmetry. :mrgreen:

    [​IMG]

    Look @ the size of that thing.

    [​IMG]

    Wow, did a lot t'day. Get a big rush from it now. Njoying little me very much.
     
  7. SiR-ROUND

    SiR-ROUND Sr Member

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    A wedgie...

    [​IMG]

    See where this is going? Oh man I love sheetmaterial.

    [​IMG]

    Bracing for 'rounding' the back head as good as possible with cardboard.

    [​IMG]

    One in place.

    [​IMG]

    Again: see where this is going? ;)

    [​IMG]

    This wil give you a good sense I think.

    [​IMG]

    Look @ them rounded cheeckbones.

    [​IMG]

    Glad I'm having the spirit again. Yesterday I had creator's block.

    :mrgreen:
     
  8. SiR-ROUND

    SiR-ROUND Sr Member

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    Some more progress...

    But it'not that much fun with the two kids around killing eachother.
    I get distracted too much. :mrgreen:

    The easy parts, more braces...

    [​IMG]

    Overnight dry. The picture doesn't look that great.
    That's because of the flash. It's better in real life.

    [​IMG]

    And please keep in mind that when it's wood you can sand and putty all you want to get it right.
    I didn't make any details for the temples. Those won't be a problem and don't really add to the overall idea I wanna get from the proto.

    [​IMG]

    An eyebrow template. Since the eyes are the difficult part, I'm gonna use lot's of templates in pieces and then hope to join them together.
    That way you'll get the 'solid' feel a little more.

    [​IMG]

    Doesn't he look happy now? ;)

    [​IMG]

    Cheekbone template...

    [​IMG]

    Now it's starting to look like something. :D

    [​IMG]

    3ft distance ;) A tad outta focus, but man...
    Looks nice already if I do say so myself.

    [​IMG]

    Hopefully t'night I'll do more.
    MiL is comming over so you never know.

    :mrgreen:
     
  9. Mxlplx

    Mxlplx Sr Member RPF PREMIUM MEMBER

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    Wow, I'm going to be watching this thread with great anticipation. Great Job. I'd love one of these some day, along with the rest of the robot too.
     
  10. Dean O

    Dean O Well-Known Member

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    Very impressive work.
     
  11. TMP

    TMP Sr Member

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    WOW.. Makes me want to ask a question i know the answer to already.... "IS THIS FOR REAL" Seriously that is amazing to se how you build it up. Keep on with the progress i am very impressed.
     
  12. Hairyloft

    Hairyloft Well-Known Member

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    Really cool to see this from the start I'll keep watching. :thumbsup
     
  13. zorg

    zorg Master Member RPF PREMIUM MEMBER

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    cool job, i have one of the heads in your pictures and yours looks pretty close

    well done
     
  14. armourerdoug

    armourerdoug New Member

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    I was lucky enough to be one of three people to re build the original ABC robot from yhe movie, for a private collector, It was a lovely job to do and he now has the full animatronic head too.

    Doug
     
  15. Mxlplx

    Mxlplx Sr Member RPF PREMIUM MEMBER

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    armourerdoug, do yo uhave any pics of the rebuild? I'd love to see them. As I'm sure we all would
     
  16. Jimbo890

    Jimbo890 Well-Known Member

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    Great scratch build job. Keep us updated. give me some ideas on how to do some projects I'm working on.
     
  17. SiR-ROUND

    SiR-ROUND Sr Member

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    And here I was thinking nobody cared...

    :$

    Must be something wrong with my notifies...

    :D

    That's an honour comming from you, judging ur site. :eek

    Thanks for all the praise. I think I found a new hobby in making props.

    Wow a whole robot... And the original animatronic? The guy must be loaded...

    A fullsize wouldn't fit in my Home Cinema, but I will someday have a fullsize Robocop.

    :love
     
  18. Scapey

    Scapey Sr Member

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    Woo.
    You're proving something that I've long suspected could be done, and intended to try out.
    Mind if I save YOUR pics for reference? ;)
     
  19. darcjedi

    darcjedi Well-Known Member RPF PREMIUM MEMBER

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    i have some reference photos i scanned from the art of book, some of which show the robot under construction... you can snag em here

    -Jeff
     
  20. SiR-ROUND

    SiR-ROUND Sr Member

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    Thanks very much. Although I do have the book, I didn't scan the pics yet.

    This way I can safely glue all over the place. ;)

    @ Scapegoat.

    Well, let's see... I started my thread in two seperate public forums.

    You can safely assume you can save the images. I'd feel honoured.

    B)
     
  21. Boba Frett

    Boba Frett Sr Member

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    Very impressive :)
     
  22. Too Much Garlic

    Too Much Garlic Master Member

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    Coming along nicely. Love the progress pictures. Way cool. .)
     
  23. Scapey

    Scapey Sr Member

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    You owe me two new mouse buttons now, man.
    And .5mm of skin, from all the clicking and saving ;)
     
  24. SiR-ROUND

    SiR-ROUND Sr Member

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    Gegegege LOL... And thanks.

    I could just email you the pictures... :angel


    Started of with some easy stuff today.

    Decided to fill the jaw.

    [​IMG]

    [​IMG]

    Made some teeth...

    [​IMG]

    [​IMG]

    Dry fitted...

    [​IMG]

    [​IMG]

    I do think that the real ABC didn't have a closed jaw.
    Judging from the picture below, you can see the piston through the back of the jaw.
    I'll make mine the same, so open jaw it will be...
    I'm also very curious about how the pistons really were connected.
    The kit just has some rods. I'd like to do some more lifelike pistons.

    [​IMG]

    Glued on the other temple.

    [​IMG]

    On with what I've been delaying, the eye...
    The following pics are the stages needed to somewhat get close.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    On the picture below you can see that there actually should be a flat piece on the cheekbone, just below the eye cavity, hmmm...
    Save that for the wood.
    You can also see the slight curved top of the head.
    Also not easy with cardboard.

    [​IMG]

    The paper eyebrow needed some reinforcement to get a better idea.
    I'll replace the paper with more sturdy cardboard when I'm satisfied with the template.

    [​IMG]

    A general idea... Needs more work.

    [​IMG]

    And to end with glueing the right temple secure for overnight drying.

    [​IMG]

    I do need some more pics to get the detail for the eyes right, so hopefully someone provides me with pictures of the kit in different angles.

    I do tend to worry about the details, but I really shouldn't because it's only the proto.

    Greets.
     
  25. Darth Infamous

    Darth Infamous Sr Member RPF PREMIUM MEMBER

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    WoW...very nice thread. Great job so far. The creativity on this board is awe inspiring.
    Looking foward to seeing more progress pics. :)
     
  26. Jedifyfe

    Jedifyfe Master Member RPF PREMIUM MEMBER

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    MORE, MORE... I WANT TO SEE MORE.... This thread is really cool man. I love the progess pics.......... :eek
     
  27. SiR-ROUND

    SiR-ROUND Sr Member

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    :$ Yee thanks... :$

    BTW...

    Is it build or built? I really don't remember the grammar for this...

    :unsure
     
  28. Too Much Garlic

    Too Much Garlic Master Member

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    Built if it is past tense, build if it is present tense - as in something you are doing now. It all depends on the sentence and in what way the word is used. Hope that helps.

    I'm really impressed with this topic. Can't wait for more updates.
     
  29. SiR-ROUND

    SiR-ROUND Sr Member

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    Thanks. Well, I'm still building so build it stays... ;)

    I burned my thumb yesterday making Lasagna for the kids, so I'm waiting for the blister to reduce a little before finishing the outer eye sockets.

    :cry

    Oh and got another project waiting already... Robocop feet remade out of wood for a supertight new cast. Won't get into that now. First the head has to be finished.

    Any tips on casting and molds would be very welcome. I don't know how to do that. I see pictures of the GA kit and I don't get how it's possible to do in one piece.

    Well, still got quite some time to learn before I'm done.

    Keep yall posted.
     
  30. hollywoodhardware

    hollywoodhardware Sr Member

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    Here are pictures of the movie mold. I sold it to GA some time back and he used it for his ABC kits:

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Thomas

    edit: pic urls
     
  31. SiR-ROUND

    SiR-ROUND Sr Member

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    Great stuff.

    Now I know what the bottom is supposed to look like.

    Thanks very much Thomas....

    :thumbsup
     
  32. frosty

    frosty Sr Member

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    Looks great, i saw the full prop in storage at ellstree around the time of the phantom menace, a company called weird and wonderfull had that and a lot of cool props in storage, they had a lot of stuff, yours looks great.
     
  33. BlindSquirrel

    BlindSquirrel Sr Member RPF PREMIUM MEMBER

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    This is looking great. Good job.. I can't wait to see the final head.
     
  34. SiR-ROUND

    SiR-ROUND Sr Member

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    Thanks guys.

    Somehow my notifies are gone for this topic. I xperience this with one other board also.
    Strange... * those cookies.

    Coming from someone who saw the 'real' thing that's indeed a big boost of convidence for me.



    Little progress.

    Minor cutting needed on the paper template.

    [​IMG]

    Removed the template again and copied it onto cardboard.

    [​IMG]

    The sides are glued. Have to wait for it to really dry overnight.
    Bummer. But after that I can glue some more.

    [​IMG]

    Those eyes will also be a problem recreating in wood, but at least I can then sand and putty all I desire to get it as right as I think it is.

    Does anyone have any info about the connections of the pistons? I have a HDTV cap of the movie that shows pretty good detail on them, but especially on the jaw it's difficult to see what wa sused. The big pistons on the side look like they are connected with some kind of ... Well we call it 'cardan' joint. You know the ones they use in 4WD model RC cars. TIA for the info.

    That's all for t'day folks.

    ;)
     
  35. SiR-ROUND

    SiR-ROUND Sr Member

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    Again some minor work, but the glue needs to dry anyway...

    [​IMG]

    [​IMG]

    Underneath the cheekbones

    [​IMG]

    Now only the eyebrows and we have the normal frown again.
    The cheekbones will need work when it's made out of wood. There is that flat area that I cannot recreate. Well I could, but it's to much work and not nescessary.

    [​IMG]

    It's gonna be a bad *....

    [​IMG]

    Till again...
     
  36. Chewie15

    Chewie15 Sr Member

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    This is frickin sweet.... it's cardboard..... You the man ;)

    H
     
  37. SiR-ROUND

    SiR-ROUND Sr Member

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    Thanks.

    Based on the original molds pictures posted, I now know what the bottom looks like. The upper jaw is closed not open.

    But you never know...

    On those same images the lower jaw is closed like the kit, but looking at screenshots it really isn't. You can see the neck pistons through the jaw.

    Anyway, added the flesh between the jaw and the cheeks.

    [​IMG]

    Not fully in position yet, I want to let the glue dry first.
    As you can see the right eye on the picture has given up on me.
    Somehow there is strain on that part that isn't there on the left.
    Let's say cardboard is very forgiving when it comes to slight differences.
    And in this case, adding all the minor measurement errors bursted out on one eyesocket. :D Will fix it though, I fix everything...

    ;)

    [​IMG]

    Somehow the jaw now seems to be bigger... Hmmm...
    The major thing wrong with it are the angle of the eyes. They are too catlike. Will fix that eventually.

    This is good comparison...

    [​IMG][​IMG]

    Still more to come...
    As long as I don't find a secondhand jigsawmachine anytime soon...
     
  38. BlindSquirrel

    BlindSquirrel Sr Member RPF PREMIUM MEMBER

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    Fantastic. It's really coming along. I love all that Dredd stuff.

    I just noticed... on the original, is the lower jaw actually two pieces? It looks like the little box that sits on the jaw is offset slightly.

    (sorry I didn't notice sooner)
     
  39. buckettt

    buckettt Well-Known Member

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    That looks great...I've been putting off making the abc robot forever....I always thought it would be so frikin cool to have that big heap filling up a corner of the room...have you thought about using sintra?? something you can cut, glue, sand, mold, paint etc..??..good luck..it looks really good.....you could even do a little of the shoulders and make a nice bust statue :)
     
  40. SiR-ROUND

    SiR-ROUND Sr Member

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    That's correct. I started with the lower jaw and got more detailed along the way.

    I'll correct that piece when I make the jaw white also. To get the general idea, the head should be somewhat in one color I think. ;)

    @Buckett, what is sintra? :unsure Is it something like balsa or is it plastic?

    If this were to be a bust it would be huge. But there's to much info missing for the whole thing. There's only so much I want to guess on a project like this.

    I'll do the wishbone and as many pistons around the neck as I can.
     
  41. buckettt

    buckettt Well-Known Member

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    I hav'nt used it before..but I know alot of guys here do...I think its like styrene...basically pvc/ plastic sheets that come in different thicknesses and are easy to cut, glue, and trim, and sand, and I guess you can warm it up and mold it..and paint it etc....so I guess you could say plastic balsa wood..

    like I said....I havn't used this so I'm sure someone else can give you better info..
    but I would think it would be something you would want to use on this project...
    do you have any rough measurements for how big you made the head??
     
  42. PHArchivist

    PHArchivist Master Member

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    Awesome project.
     
  43. Aegis159

    Aegis159 Sr Member

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    One of my favorite robots out there, I wish they would have shown more of him in the film.

    I've been lucky enough to poke and prod around on the real thing... and it's massive in person.. Definately an awesome piece to see "in the flesh" as it were, hehe.

    One of these days I'm going to get started on my head kit as well.... I finished the little one, now I just need to do the big one..
     
  44. Neon Sentry

    Neon Sentry Sr Member

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    I also planned on attempting an ABC bust from scratch one of these days... the film had a suprising amount of really strong designs. Can't wait to see this puppy finished :D
     
  45. SiR-ROUND

    SiR-ROUND Sr Member

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    Well, the molding would be a major advantage when doing the curved back of the head. Ofcourse it then also has to be able to stretch.

    Hope somebody pitches in on the subject. The name is propably different here in Holland, so I don't know if I can get hold of it. But thanks very much for your 2 cents.

    :thumbsup

    Oh, another thing. One major advantage would be the flat surface ofcourse. Balsa is also pretty flat as is, but it needs some priming and maybe filling.

    @ PHA, thanks man.

    @ Aegis, Oh how I would like to see the real thing, and might I add, take tons of pictures of it.
    So you finished the Tsukuda or a recast? And do you mean your own head kit or the GA one?
     
  46. SiR-ROUND

    SiR-ROUND Sr Member

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    Hi Neon.

    Crossposted, so saw ur reply just now. Another Robo/Dredd fanatic.

    NICE.

    :D
     
  47. The Hopkinator

    The Hopkinator Sr Member

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    *. I cant even close a cardboard box. Thats just incredible.
     
  48. SiR-ROUND

    SiR-ROUND Sr Member

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    Did you try with tape or the more complex way of crossing the flaps?

    :D
     
  49. fettster

    fettster Sr Member

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    fanstatic, stunning, amazing, superb and all of the above
     
  50. Mantroon

    Mantroon New Member

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    I gotta agree. The design of the judge dredd movie was fantastic, and this head construction looks spot on.

    I can't wait to see it completed.
     

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