ABC warrior construction thread

Discussion in 'Replica Props' started by oota goota, Feb 15, 2012.

  1. oota goota

    oota goota Well-Known Member

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    Hi all this thread is for sharing construction ideas and images for anyone who actually is getting around to making an ABC warrior Hammerstein style.

    There is a reference thread here http://www.therpf.com/f9/judge-dredd-abc-warrior-references-134686/ with some others construction,s ome high def pics and some dimensions.

    If anyone has any ideas to share about how to tackle this project please post it here!
     
    Last edited: Feb 17, 2012
  2. oota goota

    oota goota Well-Known Member

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    I'll go first! My construction thoughts go something like this

    armiture - Steel pipe with scaffolding joints
    Feet - mdf, pipe, resin details
    knees - mdf and possibly vac formed 'knee caps'
    thighs - vac formed pieces - possibly generic for each leg
    groin/ butt - mdf
    chest - plywood frame clad in plastic and metal
    back - plywood frame clad in plastic, mdf boxes etc
    shoulder pads - 1 style ply frame, plastic cladding or possibly vac formed
    biceps - vac formed generic for both arms
    forearms - vac formed generic for both arms
    Hands - mdf, aluminium
    Head - mdf with cd tray for back part of head which would be vac formed

    Finish - Possibly graphite powder and resin coating (i have never tried this)
    misc pipes and cables dressed in to match film robot

    Also need to make an ABC graphic for a badge on the left shoulder pad. Should look like stamped steel

    Additional components might be:
    a helmet
    more body armour (eg stomach) to make it less like a stripped down robot and save a bit of hassle with cables
    a hammer

    okay that's pretty much as far as I have got. Getting a vinyl kit in the post. will probably tackle a shoulder pad first just to get going
     
  3. EIDesignStudio

    EIDesignStudio Active Member

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    Gezz man bet me to the punch seem like you have gone a lil further in thought then me. if you need help graphic wise i am a graphics artist...shameless plug...

    Ok Oota how do you want to break this down for ideas many points also who it's built will determin (typo) how it will be displayed like standing, sitting , storage mode like in the first shoot of him in the movie kinda like he is in a kind of ball or tucked in.. i mean we can talk this till we figure out every aspect .. I think this could be a epic thread .. I have some ideas on certain parts of the body only good pictures i have found is some one has done on here . I will ask them if i can use there pictures in this thread before dropping and photos or photo shopping them to show what i mean..
     
  4. oota goota

    oota goota Well-Known Member

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    ha ha yeah sorry just thought what the hell I might as well start a thread :)
    Yes I think will be a rather long thread by the end. I'm sure it will take me years to make this thing....

    That's a good question about posing the robot. I think mine will be pretty static but I'd like to have either:
    * a sense of movement but not as much as the vinyl kit
    * a 'de-activated' look maybe slumped over a bit, lots of rust and dust etc

    Another thing to find out is who made the original movie prop? I have checked the credits to try and find out who the original sculptors were but it's not clear to me
     
  5. EIDesignStudio

    EIDesignStudio Active Member

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    Okie dokie geez i need to learn how to spell. O well .. I did some digging about 15 mins worth imdb and looked at the credits and chased down each company listed searched there site i got nodda so next step was I fired off a email to each company asking them what roll they played in the movie and why. Saying I looking for some screen used props if they had any that was not on the market yet.. so here is the fx companies listed for the file with what they did:
    Special Effects

    Asylum Models & Effects (specialty props)
    Computer Film Company, The (CFC) (additional digital compositing)
    Digital Fauxtography
    FB-FX (costume armour)
    Manex Visual Effects (MVFX)
    Mass. Illusions
    Pacific Title and Art Studio (visual effects opticals)
    ReelEye Company (special effects contact lenses)

    Ah HA!!! as i was typing this out i did a google search to look for a photo to show you how the legs were done in the static prop and BAMM there is the all the info on the artist who made the orginal scale model used for the movie. His name is Chris Halls here is a link to that page I found on him and the making of the prop.. @ gold stars link ok after all that I forgot what my was going to say so give me a min to figure it out and then we can start break this puppy down ..


    Here is another link on him using his real name and bio link

    I think the reason no one could find any real info is cause no one knew what it was called we all just called it ABC warrior when he named the one in the file "mean machine" so here is the link to him. link
     
    Last edited: Feb 15, 2012
  6. EIDesignStudio

    EIDesignStudio Active Member

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    Crap i got the name wrong. of the warrior (face slap)
     
  7. oota goota

    oota goota Well-Known Member

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    Nice work!

    So Chris Halls (Cunningham) designed the robot and built a scale model. Presumably Asylum Models & Effects made the full scale prop? Or Mass Illusion?

    The credits have Joss Williams as Robot supervisor, about 4 robot engineers and 1 robot electronics technician.

    It would be great to try and track down someone who built to talk about process and materials. The body all looks like fibreglass to me...
     
  8. EIDesignStudio

    EIDesignStudio Active Member

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    looking at the picture of them building the standing version it's nothing but A frame style leg setup till it gets to the knees and tilts backwards with a same setup on the top. It's hard to tell from the picture since it was so small but i bet it was some sort of four link set up. no matter on how you make it you should make it with the joints so you can take it down for moving or storage..

    Ok on to my ideas how I would do this project as I said before if I good working base or have a buddy sculpt one up from scratch.. My version will be metal out of metal instead of glass. Going off the model I will use a process called "flow forming" for each piece i will have to make a wooden or bondo buck. this way will cost me more in the long run but it will be a one off when I'm finished. I think Me and Oota are on the same page as far as making the head open to show the wires and stuff. my idea on this would be to use a Servo on rod setup and instead of having to use a r/c controller for it I would just wire it in like it was the used in the movie using a micro switch and stepper. if you look at what appears to be a breadboard you notice there is a little switch looking button on the side. so just put it on the back side of that you can hide it in the larger cup looking thing just make the center point little circle the hidden switch see the attached photo.. [​IMG]


    I'm going to make this kinda of a all in one on the above question about head tray opening. I agree with you on a cd/dvd style of set up. I think it will break down to the amount of space and weight which is TBD . [​IMG][​IMG]
     
  9. oota goota

    oota goota Well-Known Member

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    I really like your idea of a button in the temple opening the back of the head. Brilliant! I vote option 1

    I have considered making a buck and vac forming the head completely...dunno yet not sure how well that would go.

    Kustom can you tell a bit more about flow forming? sounds interesting I am not familiar with it
     
  10. EIDesignStudio

    EIDesignStudio Active Member

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    To answer your above question I would want to say Asylum but after doing more reading I think since he designed the org. comic book mean green from the start i want to believe he was brought is as a contractor for the job and he worked alone at the start. And then another fx company came in to assist him.

    Flow forming is using a power hammer or rivet gun with special heads on it to form sheet metal in a buck of some sort. instead of hammer and dolly ways. it will make the parts cleaner in the end vs getting all the dings out after shaping the piece.. here is a link to a video that show it being done. I was lucky to attend a workshop so i learned him. link
     
  11. jediscout72

    jediscout72 Well-Known Member

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    I based alot of my custom build off the ABC robot reference shots, heres my custom built

    [​IMG][​IMG]
     
  12. oota goota

    oota goota Well-Known Member

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    yeah it's not clear I think. A job that big I reckon you'd need a few different fabricators, especially if you have to work with a engineering team


    That's amazing! it looks really effective and your finished product would be MEAN!. I didn't catch what material the buck was made from but it would have to be very hard I imagine.

    Would you do an internal buck or external one?
     
  13. oota goota

    oota goota Well-Known Member

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    Hey that's a great build jediscout. I was wondering what happened to that build, you've got a thread on the rpf right?

    It's freakin' huge! The leg pieces look great, care to share how you made it?
     
  14. jediscout72

    jediscout72 Well-Known Member

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    Thanks! yah its been a work in progress for over a few years now, as all the parts are either found or donated. Its in its like seventh incarnation. Always upgrading when i find new parts. Alot of vaccum cleaner parts, nerf guns,real saw blades, 12 volt craftsman drill, kids toys,various rubbish bins, planters, hair dryers.and various tubes,wires and cords. I kinda wanted ABC mixed with the giant samurais cyborgs from Sucker Punch.
    It sits up on 4 ft stilts. and yes this costume is wearable, i did a fashion show in it last year, but i had legs strap malfunctions.

    [​IMG]
    [​IMG]
     
  15. EIDesignStudio

    EIDesignStudio Active Member

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    dude that is just killer and you wear it . Well if I'm making parts for mine and ask for a piece here are there I think i can help you out....

    The forms can be made from wood or kitty hair bondo depends on the size of the piece and how many parts will be made from it.
     
  16. oota goota

    oota goota Well-Known Member

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    So I have started trying to work out dimensions.

    According to the measurements that Zorg provided on Sir Rounds thread the width of the head across the brow is roughly 143mm. If you take that measurement and apply it as a ratio across the shoulder pad you get about 350mm. The width of the chest is about 560mm.

    Anyone got any other measurements? I make the total height of this beast to be about 270cm

    I'm waiting for my vinyl kit to arrive :(
     
  17. EIDesignStudio

    EIDesignStudio Active Member

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    I'm waiting back to find out if my buddy is getting the head if you can wait I plan on making a blue print from it. :0
     
  18. oota goota

    oota goota Well-Known Member

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    Hey that will help alot for accuracy and hell yeah I'll wait for a blueprint! Very generous of you to share it by the way.

    I'll be making the head last I think
     
  19. EIDesignStudio

    EIDesignStudio Active Member

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    So oota did you get the foot done yet it's been 24 hours? what is your plan of attack on them you going to do some tracks or flat bottom? I've been working on the moving parts till i can get a head to look at. cheapest and fastest way to make a tilt and pan neck joint for movement is using a Caster :) that is how i plan on attacking the neck on mine.. just 2 cents
     
  20. oota goota

    oota goota Well-Known Member

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    ha ha!! sadly its all just in my head at this stage

    I'll definitely do tracks of some sort but I'm not sure how articulated I am going to make it. I think if I can just get the basic bits all made I'lll be doing well :)


    That's a good idea using the caster. I'm looking forward to seeing how your build progresses
     
  21. EIDesignStudio

    EIDesignStudio Active Member

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    If you want to do the track version. I found something you can use as a quick to use as track wheels if you look at some plastic beach chairs with the wheels on one end. I was just out side and it popped in my head I would need a good picture of the foot so i can break it down. but its a start..
     
  22. oota goota

    oota goota Well-Known Member

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    yeah i guess it will depend if you can find them the right size! I'll probably just fabricate something and do some casts.

    good news is that blaxmyth is working on a set of dimensions too!
     
  23. EIDesignStudio

    EIDesignStudio Active Member

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    I not figured out if I want to try and move him or not. I don't want to get in over my head dealing with extra motors and such. I want most of the automation to be on it's own I don't want to use a remote on the face, hands, arms. I spoke to a buddy today to see if i can make him stand up from the position like he is in the first shot with him. We drew up some ideas but hell that is almost like getting a full on movie prop. best i came up is a canter leaver set up attached to the back. with double 4-link leg joints above and below the knee area. if i choose to go that route I would have to use a small set of airbags to cushion the drop so it does not slam from the weight.. like i said this is not a weekend project for me. but when i start it should go smooth. I dug out about 15 grand scale servos I have from some old planes. I figure I have 2 weeks before I can start and blue print the head. OOta when you get your kit can you take some high res pictures and scale it up and I will design each part for the blue print. I figure if if goign to be done might as well go all out....
     
  24. oota goota

    oota goota Well-Known Member

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    okay kustom will do :)

    there's a production shot somewhere of the abc warrior in sitting position. Looks like they replaced the feet with long steel 'skis' presumably to help with the weight and balance while it moves
     
  25. EIDesignStudio

    EIDesignStudio Active Member

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    I don't know if you wanted me to put this here. but here is the logo i did for the
    Hammerstein . so every one can use it if need be..
     
  26. oota goota

    oota goota Well-Known Member

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  27. EIDesignStudio

    EIDesignStudio Active Member

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    not a problem. I'm looking for all the other versions I will make them up as well.
     
  28. oota goota

    oota goota Well-Known Member

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    I've put a couple more pictures up on the resource thread
     
  29. oota goota

    oota goota Well-Known Member

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    here's a quick mock up I did of the ABC graphic. I think I might vac form this piece so it looks a bit more like stamped metal

    [​IMG]

    anyway it's just dipping the proverbial toe in the proverbial water :)
     
    Last edited: Jan 3, 2016
  30. EIDesignStudio

    EIDesignStudio Active Member

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    it was hard to tell due to the angle of the picture so i did thee best with what I had.
    Ok i need some input here. I will start to do some rough blue prints of the basic shapes I have on hand or pictures. I was thinking of doing this two ways I can scale up each part to size but you would be printing a lot of pages. easy for me since I have a large scale printer.54" wide... Or i can break each part down like jaw on one page with the different views and do the sizes on the piece in place. I will not be doing a cad lay out but it will be as close to it.. let me know..
     
  31. EIDesignStudio

    EIDesignStudio Active Member

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    I should edit the upper post. I did the math today. I might have to scratch the whole making it out of metal at first. I think for speed of building and to make sure I can the right mechs in place at first i will do a resin one then when money and space frees up. will build a whole metal one. I'll make my flow forming molds anyway... so far I have figured out in one hand I will need 7 servos in the hand and wrist for pan and tilt. I could tie all the fingers to 1 but I would like to adjust each one. for doing the elbow I think a worm drive motor or make it a simple cable push and pull setup like a tentacal (typo) mech. I have a buch of differnt servos on hand from high end to low buck plastic ones I will have to see what they can handle. if I can save money in one aspect it can be used for more details in the long run..
     
  32. oota goota

    oota goota Well-Known Member

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    Dude your ABC build is going to be epic!
     
  33. Ghostsoldier

    Ghostsoldier Sr Member

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    ^^^This!^^^:thumbsup

    Rob
     
  34. EIDesignStudio

    EIDesignStudio Active Member

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    thanks for the kick in the tail.. I am waiting to hear back from Smooth on about the correct products to use.. instead of making hard molds I think I will just use rubber. plus I hope i can use the proper casting resin so it will be lighter and stronger then fiberglass. I'm making up my list and just need a small model kit to do the scaling up on I think i found some for around 20 or so bucks. i figure i would as here so i don't buy any junk.. where are ya'll getting the kits from...
     
  35. oota goota

    oota goota Well-Known Member

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    I just got mine off ebay, turns out its a recast but its still roughly 1/9th scale. There is some minimal warping and shrinking but I am only using it for scaling up to 1:1 so it really doesn't matter that much. So if the model is 0.5mm out that only equates to 4.5mm in 1:1 scale. I can live with that :)

    I reckon you should pick up a kit it will help with your build getting a 3d model.

    Casting resin is cool but very brittle. Are you going to back it with something?
     
  36. EIDesignStudio

    EIDesignStudio Active Member

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    yea I agree I can't just use your pictures all the time..:behave. I will look for a kit today and order one.. I am waiting to hear back from smooth on I told them the specs of the project and it needs to be strong and lightweight. so i will see what they tell me. i figure so far each finger will be a 2 part mold so i can wrap it around the the mech and use tiny screw and nut. i will prob cast the nust in the mold to it will be in the finish product. thinking ahead i guess. who knows.. :confused
     
  37. EIDesignStudio

    EIDesignStudio Active Member

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    Ok I had some spare 5 mins today so I figured I would show a preview of what the blue prints will look like. this is a sample so not much info. you will notice it has one blue line that will be the span sizes for each part. I will do my best to make a 3 version view of each piece as in eye section will be dead on, left and right side. I know i'm new here but I do not want people to think I'm full of BS and can't do anything but talk smack.. once my noob status wears off I plan on joining the membership side of the site. if you can think of any thing as far as the way this should look please let me know.. these will not be to scale. I do not want people to have to print out 15 -20 pages.. Enjoy and thanks
     
  38. oota goota

    oota goota Well-Known Member

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    Hey Kustom that looks like a great start! a really good profile view. Something that might be useful is some kind of scale so that people know how much to enlarge it to get 1:1 scale. nice work.
    I am also very new here but i have found people to be very welcoming and helpful, this is a great site!
     
  39. EIDesignStudio

    EIDesignStudio Active Member

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    this is what i was planing on doing with it the scale in this is fake just to show. see if this makes it better for you to under stand
     
  40. Beaker

    Beaker Active Member

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    Very cool thread! Will be watching... LOVED the ABC warrior the first time I saw it!
     
  41. oota goota

    oota goota Well-Known Member

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    Awesome Kustom its perfect!
     
  42. EIDesignStudio

    EIDesignStudio Active Member

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    ok here is a thought I need to make the control board I thinking a simple radio shack bread board. I trying to figure out how to make it spark if I wanted it too. I will have to study some screen shots to get the color wiring correct and such.. BTW I got to meetup with Beaker @ smooth on killer place to visit and good people.
     
  43. Tobot

    Tobot Active Member

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    A great addition would be a Hammerstein headpiece with the wires hanging out
     
  44. EIDesignStudio

    EIDesignStudio Active Member

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    I have a few ideas in mind as for as kits go. like the one you said as well as a bust ( a static or a servo and led one) then the whole 1:1 scale kit static or some servo driven parts. I will see what the budget comes to for this and see what can do.
     
  45. oota goota

    oota goota Well-Known Member

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    yeah i agree Tobot that would be a cool, also a detachable hammer!
     
  46. Monk

    Monk Active Member

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    does anyone have access to a 3D model of this? something done in Maya or 3DMax?

    I'm hoping to do some Pep unwrapping of it.
     
  47. oota goota

    oota goota Well-Known Member

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    A pep of this beast would be great.

    EIDesignStudio has been working on some blueprints, that's as close as anyone as got.
     
  48. EIDesignStudio

    EIDesignStudio Active Member

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    Sorry for the delay . I got out the hospital this week. I'm sorry there is no pep file on this project after Ive been studying this it would be a nightmare to do. I got the parts i needed to start the side plates From art as well so I will make copies of them so i can them back to him asap. My health is down hill so please bear with me in this time. I working on this when I have the ooph to do it. Trust me the passion is there and so is my will.

    As far as a update I got the head in the 3rd round of primer and blocked. The jaw I'm still want to get some details right. I don't like how the bolt teeth are done i might cut them off and redo them. I am also on the fence about re drilling the bolt holes on the head and replacing the allen screws due to a poor casting so the details will be there it's not biggy. I just tryign to figure how far to take this. I don't want to turn out a **** pour product incase some one wants one from me. All i want is the end user to do is just scuff and paint no defects to deal with.
    Thanks again for understanding
    Gary
     
  49. oota goota

    oota goota Well-Known Member

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    take care of yourself dude! Can't wait to see progress pics :)
     
  50. oota goota

    oota goota Well-Known Member

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    Holy crap I have finally started this project!

    It's taken awhile to get going but I've decided rather than tackling the head as most people seem to do I am going to start from the bottom up (maybe it's a southern hemisphere thing) and start work on the left leg.

    I'm primarily using the hammerstein 1/9th scale kitset as reference. I'm not really drawing up to many plans just using a set of calipers and scaling up the dimensions of each 'shape' on the leg......make enough shapes and glue them together and a leg should emerege.

    After mucking around a bit with some materials I'm going to use mainly 12mm ply for my structures because:
    * It loves superglue
    * It's easy to work
    * I want to avoid things like polystyrene or clay or anything that might need a mold later on
    * I have a pile of it at home :)

    I'm going to clad as much of the ply as possible with either styrene, pvc, or ABS in order to help achieve a weathered metal look later on IF I ever get that far. I'll try and do one leg and see how it goes. Admittedly having a robot leg in your house isn't as cool as having a head in your house

    I've started chopping up ply for the bottom foot piece but in the meantime I've made a ply frame of the upper leg armour.

    Any and all comments and criticisms are welcome. If you can think of a better way to do this let me know!
     

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