ANH Stormtrooper Helmet Project
- Thread starter chris08234
- Start date
chris08234
Well-Known Member
Yep I TK560's site before. That was my next step is to build something similar to tk560's tutorial. His is awesome. I was just hoping to get my helmet made before I spent too much (being close to my daughter's first xmas) on my new found hobby. I will probably regroup this weekend.
Yep I TK560's site before. That was my next step is to build something similar to tk560's tutorial. His is awesome. I was just hoping to get my helmet made before I spent too much (being close to my daughter's first xmas) on my new found hobby. I will probably regroup this weekend.
Yep I TK560's site before. That was my next step is to build something similar to tk560's tutorial. His is awesome. I was just hoping to get my helmet made before I spent too much (being close to my daughter's first xmas) on my new found hobby. I will probably regroup this weekend.
chris08234
Well-Known Member
ANother update. Disaster has struck :cry . My sculpture was damaged while removing it from the ABS. I was able to get a decent pull (still far from acceptable) but had lock down. "I'm afraid he's more Bondo than man now, a twisted......" I have already started repairing the sculpture.
My concensous is that I need to go to a lighter guage ABS. Possible .090" in lieu of .125". I need to do my homework.
My concensous is that I need to go to a lighter guage ABS. Possible .090" in lieu of .125". I need to do my homework.
Too Much Garlic
Master Member
That's sad news. Hope you get it fixed.
Good luck, man. :thumbsup
Good luck, man. :thumbsup
chris08234
Well-Known Member
Thank you all again for the great insights. At this point I am playing with thicknesses and styrene vs ABS just to see my capabilities.
I have started construction of a table similar to the tutorial as described in TK560's website. I am hoping to accomplish a 28" to 36" square forming table if all goes well. Below is a link where I found a nice selection of oven building materials:
http://morelectric.com/
As for the sculpture, repairs have started. Unfortunately, it is progressing slowly. I am hoping to make any refinements needed. I have canned the idea of doing an inset for the frown and will cast that into the sculpture. I will follow with pictures when I get back to a more complete stage.
I have started construction of a table similar to the tutorial as described in TK560's website. I am hoping to accomplish a 28" to 36" square forming table if all goes well. Below is a link where I found a nice selection of oven building materials:
http://morelectric.com/
As for the sculpture, repairs have started. Unfortunately, it is progressing slowly. I am hoping to make any refinements needed. I have canned the idea of doing an inset for the frown and will cast that into the sculpture. I will follow with pictures when I get back to a more complete stage.
Too Much Garlic
Master Member
Hmm... sorry if it has been mentioned already... but, is your master separated in pieces - face & back/cap or is it a one-piece?
chris08234
Well-Known Member
I am using a one-piece cast. I am afraid to lose any detail in breaking it up (although I should know to do so). When vacuum forming I have created a "well" to cast only a portion of the helmet at a time. I started with the face. The lock down occured mostly because of my ignorance. I should have cut the plastic to allow me to pull it apart and over the mold. It would be tough with .125" ABS though.
Too Much Garlic
Master Member
Oh... I think it will be impossible to vac-form from a one-piece master - such a piece requires a silicone 2-part mold and either resin or fiberglass casting.
Hope someone with a lot more vac-forming experience will chime in... as I'm far from knowledgeable in that area.
Hope someone with a lot more vac-forming experience will chime in... as I'm far from knowledgeable in that area.
chris08234
Well-Known Member
I've been working on adding in the frown. Since the entire surface of my sculpture is Bondo, I have found that fine woodworking chisels can make for some really detailed work. I had infilled the original shape of the frown with Bondo Gold (easier to sand and shape than standard Bondo). Using Mascot Brand woodworking chisels makes easy work of creating the mouth vents. I will follow tih final pictures after this weekend.
A side note.....I have started construction of the vacuum form table as described by TK560. He did a remarkable job on his tutorial (both written and video). I have all the components and just need to find the time to really get things started. Thank you all.
A side note.....I have started construction of the vacuum form table as described by TK560. He did a remarkable job on his tutorial (both written and video). I have all the components and just need to find the time to really get things started. Thank you all.
chris08234
Well-Known Member
I was able to get some pics uploaded. Its still rough, but its coming together.
http://new.photos.yahoo.com/christopher_s0...460762357036811
http://new.photos.yahoo.com/christopher_s0...460762357036811
chris08234
Well-Known Member
Lots of momentum this past weekend. I have completed the oven, the vacuum forming platform is just about complete, and the sculpture is again in one piece and ready to go.
chris08234
Well-Known Member
The latest progress on the sculpture. I plan to finish it up enough to make a pull, but realize the side tubes are too low and a bit over sized. It will be a continuous work in progess. I will post some pics of the oven and vacuum form table which hopefully will be completed this weekend 100 percent.
http://new.photos.yahoo.com/christopher_s0...460762367649253
http://new.photos.yahoo.com/christopher_s0...460762367649253
chris08234
Well-Known Member
Work is proceeding. I have been fine tuning the oven and plan on remaking the vacuum forming table (as constructed the sheet metal is pretty "oil canned"). Sorry, I did not get any picture of the oven as of yet.
I have scraped the idea of making pulls from the master sculpture and have begun secondary castings and molds of the rear, dome, and face. The entire sculpture was much to tall and would stretch the plastic entirely too thin to make it practical. I'm using some alternative methods/materials in this endeavor. My castings are of plaster of paris since it is a "one and done" kinda deal. No need to get expensive materials since I can always recast from the mother mold. My secondary molds are made of two (2) layers of bondo @ 1/4 " thick each with a double layer of fiberglass mesh sandwiched in between each layer of bondo. The bottom side or cavity is then filled with spray foam insulation. It seems to be durable enough for pulls.
I have scraped the idea of making pulls from the master sculpture and have begun secondary castings and molds of the rear, dome, and face. The entire sculpture was much to tall and would stretch the plastic entirely too thin to make it practical. I'm using some alternative methods/materials in this endeavor. My castings are of plaster of paris since it is a "one and done" kinda deal. No need to get expensive materials since I can always recast from the mother mold. My secondary molds are made of two (2) layers of bondo @ 1/4 " thick each with a double layer of fiberglass mesh sandwiched in between each layer of bondo. The bottom side or cavity is then filled with spray foam insulation. It seems to be durable enough for pulls.
chris08234
Well-Known Member
Not much progress has been made due to the holidays. I have reviewed the work on the IC helmet on Imperial Commandos website. I tried my hand at casting using a silicone (using the ghetto casting method to limit costs) negative mold. Here is my dilemma:
My problem is lockdown while casting the face. Primarily the ridge that extends from the frown to the tubes. I tried to use something semi-rigid but doesn't deform. I used the silicone ghetto casting with one layer of fiberglass and some spray foam insulation so I can "pull" it apart and avoid lockdown, however, the silicone was deformed a good deal. I have to rework the secondary casting a lot before I can start any vacuum forming.
Anyone have a really detailed tutorial on casting?
My guess is also that I need to spend the money on good materials (and hope my wife does not divorce me for spending all my free time and money on this hobby). Nothing like the "right tool for the right job".
My problem is lockdown while casting the face. Primarily the ridge that extends from the frown to the tubes. I tried to use something semi-rigid but doesn't deform. I used the silicone ghetto casting with one layer of fiberglass and some spray foam insulation so I can "pull" it apart and avoid lockdown, however, the silicone was deformed a good deal. I have to rework the secondary casting a lot before I can start any vacuum forming.
Anyone have a really detailed tutorial on casting?
My guess is also that I need to spend the money on good materials (and hope my wife does not divorce me for spending all my free time and money on this hobby). Nothing like the "right tool for the right job".
chris08234
Well-Known Member
Finally got some real work completed on this project a few tweakings are needed but here is a picture of a test pull for the face mask using 0.060" ABS.
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