alienbuilder
Sr Member
Re: Aluminium cast Clone Trooper Helmet
thanks for all the kind comments.
so, today we cast bronze and aluminum and of course the helmets were cast too. unfortunately the surface is not really perfect everywhere. some areas are looking really rough and i don't know why, so don't the founder. well its not as bad as it looks on the photos, but means a little bit more work: sanding sanding sanding. and welding. just started a little bit today, but that will be my job the next few weeks. on the other hand, all the deep areas and fine details are looking well. thats good. the cast in nuts are working also very well, so i can screw in everything perfectly. i already got some visors for welding to put in as lenses and orders a green mirrored motorcycle helmet visor for the free helmet.
well here are some pictures now:
after we ve put all the molds out of the oven, we had to pack them into jute drenched in fresh plaster to stabilize the molds. as i said, the material is pretty soft after the burn out process.
while preparing the molds, the aluminum is melting in our induction oven (without any flames, just by induction. pretty fancy)….
after the plaster is hard, we can lay the molds to the side and vacuum clean the funnels.
than we cast the liquid metal into them.
the molds, filled with aluminium.
30 mitutes later the metal is already hard and we can break up the molds.
a first look of what was inside...
to clean everything up, we use a high pressure water cleaner.
the aluminium helmets
now i had to cut off everything, i ve had put on the helmets first in the wax.
still fits my head. lucky, because sometimes a cast can be smaller up to 2 percent.
now i ll have to make the surface smooth again.
well, as i said, I'm a little bit in anger that the surface is so rough, but at least, you may imagine what it will look like at the end. i can already imagine the look of the free helmet very fine. in my opinion, the alumium fits very well to the movie.
the one i ve started with should look better and better every day i work on it. so ill post the progress every day i think.
best greets, hinrich
thanks for all the kind comments.
so, today we cast bronze and aluminum and of course the helmets were cast too. unfortunately the surface is not really perfect everywhere. some areas are looking really rough and i don't know why, so don't the founder. well its not as bad as it looks on the photos, but means a little bit more work: sanding sanding sanding. and welding. just started a little bit today, but that will be my job the next few weeks. on the other hand, all the deep areas and fine details are looking well. thats good. the cast in nuts are working also very well, so i can screw in everything perfectly. i already got some visors for welding to put in as lenses and orders a green mirrored motorcycle helmet visor for the free helmet.
well here are some pictures now:
after we ve put all the molds out of the oven, we had to pack them into jute drenched in fresh plaster to stabilize the molds. as i said, the material is pretty soft after the burn out process.
while preparing the molds, the aluminum is melting in our induction oven (without any flames, just by induction. pretty fancy)….
after the plaster is hard, we can lay the molds to the side and vacuum clean the funnels.
than we cast the liquid metal into them.
the molds, filled with aluminium.
30 mitutes later the metal is already hard and we can break up the molds.
a first look of what was inside...
to clean everything up, we use a high pressure water cleaner.
the aluminium helmets
now i had to cut off everything, i ve had put on the helmets first in the wax.
still fits my head. lucky, because sometimes a cast can be smaller up to 2 percent.
now i ll have to make the surface smooth again.
well, as i said, I'm a little bit in anger that the surface is so rough, but at least, you may imagine what it will look like at the end. i can already imagine the look of the free helmet very fine. in my opinion, the alumium fits very well to the movie.
the one i ve started with should look better and better every day i work on it. so ill post the progress every day i think.
best greets, hinrich
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