Ok, I posted this on Doc's thread, but figured I should put it here too:
I've hit upon a combination of techniques that render a non-cracking finish and it's almost criminal in it's simplicity. Mind you, most of this is originally Doc's method.
I still found I got some cracking on the thicker foams when painting my suits, even with Doc's technique.
Then I had a conversation with a client of mine that owns a body shop. I told him about the suits and our painting woes. After I described the process, he advised me to eliminate one of the products and then use a scuffing pad.
I tried it. You wouldn't believe the difference it makes. I have a piece of 12mm foam that I painted yesterday and have spent the past day bending it, TRYING to get it to crack and it won't. Here is the method:
First off, don't use Mod Podge. It cracks to start with setting you up for failure later. Instead use good ole' Elmers Glue (white PVA). Four coats should do it. Stays very flexible when dry.
Second, use a scuff pad or very fine grit sandpaper, just scuff the surface of the glue to provide a "tooth" for the primer to grab onto.
Third, use the SEM flexible primer Doc suggested earlier in his thread. Two light coats should be plenty. Scuff this surface also with your scuff pad or sandpaper.
Fourth, apply your paint of choice. I use Duplicolor for the metal flake in the paint. Again, two or three very light coats should do it. DO NOT SCUFF THIS LAYER.
Finally, apply 2 medium coats of SEM flexible clear or "color coat" as it's called on the can.
Be sure to allow 24 hours for the primer to dry thoroughly before applying the paint. Follow the paint up immediately once it's dry to the touch with your clear. After everything completely dries (24 to 48 hours), you should have an extremely flexible surface that looks great and wears just as great with no cracking!
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Wow....that is one mean looking suit....bravo and congratulations on the shoot. You've done a good job and have provided some very useful advice for those who are still beginning or mid-way through.
Thank you a ton! Always nice to hear the appreciation! I've got two suits up on Ebay, and just wrapping up my new MK IV for Halloween. Best suit I've ever made. Pics will be coming up shortly.
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That is a very nice Chest piece. I just dismantled my chest piece and found where I can remake it with less effort. One section which consist of 10 different parts can actually be made with one large piece and some "strategic cuts" as you mentioned. Nice work!
I keep looking for ways to make the suit simpler to build and with fewer seams. Might have to put out my own modification for templates that people can use to create a better suit.
Stay tuned for my foam helmet with removable faceplate on my new suit! Oh yeah!
