Boba Frett
Sr Member
Thanks Jon , got the tutorial.
Fiberglass/Resin Molding of helmets
- Thread starter vampyregodz
- Start date
Hi again...
Like I wrote before, I´m in the process of creating an imperial/ coruscant guard costume (taken from the Luke action figure) and I still have a few question reg. sculpting/molding/casting the helmet and armor pieces...
People are telling me that the first mold/cast should be made of plaster, then cleaned up and remolded for the final fg-work. Does this mean:
- I´d have to make the MOLD out of plaster (instead of silicone)?
- I´d have to make the mold out of silicone, but with a plaster mothermold?
- I´d have to make the mold out of silicone, but then POUR plaster into it?
May sound like a dump question, but I´m confused :/
I started to sculpt the shoulder armor and want to do the helmet next. I was able to get the surface of the shoulder bell pretty smooth but would rather clean up a first pull and remold it.
Could anyone of you help me please by explaining all the neccessary steps?
I already searched the internet but still have these questions...ALL info is
much appreciated.
Thanks, Markus
Like I wrote before, I´m in the process of creating an imperial/ coruscant guard costume (taken from the Luke action figure) and I still have a few question reg. sculpting/molding/casting the helmet and armor pieces...
People are telling me that the first mold/cast should be made of plaster, then cleaned up and remolded for the final fg-work. Does this mean:
- I´d have to make the MOLD out of plaster (instead of silicone)?
- I´d have to make the mold out of silicone, but with a plaster mothermold?
- I´d have to make the mold out of silicone, but then POUR plaster into it?
May sound like a dump question, but I´m confused :/
I started to sculpt the shoulder armor and want to do the helmet next. I was able to get the surface of the shoulder bell pretty smooth but would rather clean up a first pull and remold it.
Could anyone of you help me please by explaining all the neccessary steps?
I already searched the internet but still have these questions...ALL info is
much appreciated.
Thanks, Markus
clonesix
Master Member
Markus,
I will try and answer your question as best possible, but keep in mind that to give you all the information you need would fill several pages, and all you are getting here is the Reader's Digest version.
It would help if you posted a picture, but I am going to guess that you are making the blue royal guard? Either way, a helmet is a helmet.
To all you questions: yes, dependining on what you want and how much you have to spend. I know that doesn't help much, so read on.
What I think they mean by "make the MOLD out of plaster," is for you to make a "waste" mold; a mold you only once. So it makes sense to make it out of plaster. A plaster mold is ridged, and depending on the undercuts, will most likely destroy your sculpt. A fiberglass cast is also ridged, and will, most likely, destroy your plaster mold (if you have a lot of undercuts, or detail, you may need to smash the plaster to get ther part out.). In the end, you have exchanged your soft sculpt for a solid fiberglass part. From there, you sand, putty, sand, primer, sand some more... (are you getting the idea that you are going to sand A LOT?) It is just like getting a smooth fender, it's all in how much work you are willing to do.
After you have sanded everything straight and primered the helmet, you sand it some more with 400 grit, then 600 grit, then 1000 grit. Then give it a coat of wax and buff a shine to it.
Now that you have a nice shiney helmet, you can either wear it as is, or make a silicone mold.
Hope that makes sense
I will try and answer your question as best possible, but keep in mind that to give you all the information you need would fill several pages, and all you are getting here is the Reader's Digest version.
It would help if you posted a picture, but I am going to guess that you are making the blue royal guard? Either way, a helmet is a helmet.
To all you questions: yes, dependining on what you want and how much you have to spend. I know that doesn't help much, so read on.
What I think they mean by "make the MOLD out of plaster," is for you to make a "waste" mold; a mold you only once. So it makes sense to make it out of plaster. A plaster mold is ridged, and depending on the undercuts, will most likely destroy your sculpt. A fiberglass cast is also ridged, and will, most likely, destroy your plaster mold (if you have a lot of undercuts, or detail, you may need to smash the plaster to get ther part out.). In the end, you have exchanged your soft sculpt for a solid fiberglass part. From there, you sand, putty, sand, primer, sand some more... (are you getting the idea that you are going to sand A LOT?) It is just like getting a smooth fender, it's all in how much work you are willing to do.
After you have sanded everything straight and primered the helmet, you sand it some more with 400 grit, then 600 grit, then 1000 grit. Then give it a coat of wax and buff a shine to it.
Now that you have a nice shiney helmet, you can either wear it as is, or make a silicone mold.
Hope that makes sense
Makes total sense to me, thanks...even if I´m less than thrilled to have my original sculpt destroyed after the first pull (I´m afraid of the first pull not being useful :unsure )
To clarify...I´m not talking about the blue guard, but the Luke IMPERIAL/CORUSCANT guard outfit from the SotE action figure. Know what I mean? So the helmet and armor parts WILL have some undercuts, that´s for sure.
Did you use kneadable or brushable silicone for your final mold(s)?
So it´s also possible to make the mothermold out of plaster-bandages, right?
What do you make the very first pull of?...FG, resin or plaster as well?
Will this first pull be SOLID of HOLLOW?
Many thanks for your input. :thumbsup
Markus
To clarify...I´m not talking about the blue guard, but the Luke IMPERIAL/CORUSCANT guard outfit from the SotE action figure. Know what I mean? So the helmet and armor parts WILL have some undercuts, that´s for sure.
Did you use kneadable or brushable silicone for your final mold(s)?
So it´s also possible to make the mothermold out of plaster-bandages, right?
What do you make the very first pull of?...FG, resin or plaster as well?
Will this first pull be SOLID of HOLLOW?
Many thanks for your input. :thumbsup
Markus
Boba Frett
Sr Member
Just checking your progress pics again , the new Cody stuff you added looks great :thumbsup :thumbsup
TK1536
Sr Member
Originally posted by OdiWan72@Oct 7 2005, 07:14 AM
Could anybody please answer the remaining questions I posted?
Thanks, Markus
[snapback]1091710[/snapback]
One way or another, I'd recommend covering your sculpt/model with silicon. Then back that with either fiberglass or plaster as your mother mold, either in two or three parts. Remove your model and now you have a master mold with which to make many final casts in your preferred medium. As CloneSix would say, that's the Reader's Digest version.
So it would be possible to pour plaster in the silicone mold (thin-walled to save costs, backed with plaster bandages) and make a solid cast to clean up and prepare for final molding?
Would I have to seal/prepare the silicone with PVA and wax before pouring the plaster in it?
Markus
Would I have to seal/prepare the silicone with PVA and wax before pouring the plaster in it?
Markus
Boba Frett
Sr Member
Any pics yet?
Originally posted by clonesix+Sep 29 2005, 02:21 AM--><div class='quotetop'>QUOTE(clonesix @ Sep 29 2005, 02:21 AM)</div>
pm me your email address and I will send it out to you.
Here are a few pics of the process. This is the final mold. I decided to make the mold in three pieces in order to put the seem lines in inconspicuous places. I wanted the dome in one piece and not have to clean it up.
[snapback]1086141[/snapback][/b]
I have been molding and casting for several years never made a case and I mold have a question.
I see two pour spouts sticking out of the back of the fiberglass jacket
are these for pouring the silicone into.
Thanks TK648
Reactor drone
Well-Known Member
You could also try rotational moulding with those case moulds.Instead of laying up fibreglass inside you just need a mould that can be closed off completely.Pour in the resin and rotate the mould until it has an even coating all over then rotate until the resin has set.
Obviously you need a fairly viscous resin for this process(and hopefully a fast setting one) but there are specific resins on the market for this type of casting.
No reinforcing can be added so the resin should be like an ABS plastic when set.BJB F series resins are supposed to be good for this so might be worth thinking about.
I've only used it for small stuff,Zat gun components but it should scale up alright,they make rainwater tanks with that technique.
Obviously you need a fairly viscous resin for this process(and hopefully a fast setting one) but there are specific resins on the market for this type of casting.
No reinforcing can be added so the resin should be like an ABS plastic when set.BJB F series resins are supposed to be good for this so might be worth thinking about.
I've only used it for small stuff,Zat gun components but it should scale up alright,they make rainwater tanks with that technique.
