Finished The Eighth Passenger

Discussion in 'Sculpture and Makeup Effects' started by daredevil665, Jul 4, 2014.

Tags:
  1. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Hello everyone. With this new thread starts a new replica of the ALIEN HR Giger version. This time I will try to be more technical than the previous ALIEN built by me. This new alien will have a trellis that runs the full height, which will allow you to mount / unmount ALIEN, legs, torso, arms, head, tail, rear tubes. Some of these parts will be assembled by means of magnets. I'm still undecided on the height. The original should be around 233 cm, but I'd like to get about 260 cm. It will support on a wooden base with a thickness of only 2 cm, with the ability to add wheels. The previous base was 20.5cm high. The pose will be like the one on display at the museum, because other poses that I had suggested in the previous thread are bulky and, in my humble opinion, less disturbing.

    AAA 112.jpg

    This new sculpture will be more faithful to the original, with regard to the proportions, with head and feet large, and hamstring deflated. The fill volume will be polystyrene, coated with clay / cellulose-based that air dries.



    To align the model to the original, I used this picture, I had to change by turning the chest and head, because it seems that these original parts are a bit 'drooping toward the rear.

    ALIEN CONFRONTO.jpg

    To be continued. :)
     
    Last edited by a moderator: Nov 8, 2018
    knnyjay and chefhawk like this.
  2. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: New lifesize Giger Alien Version

    Here you gentlemen a first draft of the frame. :)
    TAVOLA TELAIO.jpg
     
  3. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: New lifesize Giger Alien Version

    Hello everyone,
    I took some time off.
    Now resume the project ALIEN bis.
    I designed a cutter for polystyrene and now I'm building.
    In previous sculpture of ALIEN, I used a red-hot blade manual, but I had to leave 1 cm more material, because it is difficult to cut orthogonally and the excessive heat created holes. So, very earnest rasp, to achieve the correct size.
    With this cutter, everything should be more comfortable and precise and allow me to cut the finite size + 1mm.
    It can cut a maximum thickness of 570mm. is adjustable in height, through a vertical register and a horizontal recovery of harmonic steel wire 0.5mm thickness. Will have a potentiometer and a 100 vatt transformer.
    The base is of plywood 1000x1000x15mm, on which pennellato three coats of primer and two protective wax.
    It's nothing incredible, but perhaps someone may be interested to build one.:)
    Here are some pictures...


    IMAG1416.jpg IMAG1417.jpg IMAG1407.jpg IMAG1408.jpg
    IMAG1409.jpg IMAG1418.jpg IMAG1419.jpg IMAG1420.jpg
    IMAG1421.jpg IMAG1422.jpg IMAG1423.jpg IMAG1424.jpg IMAG1425.jpg

    Greetings and see you soon.
     
    laellee, Leigh and SKS Props like this.
  4. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: New lifesize Giger Alien Version

    WOW! this is all looking very precise :thumbsup
    :)
     
    daredevil665 likes this.
  5. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: New lifesize Giger Alien Version

    It works !!!
    I can use any section of harmonic steel wire and any length in the range from 150mm to 550mm, because I can adjust the amount of electric current with the potentiometer, from zero up to melt the wire. Size also fit the extruded polystyrene XPS, that with the normal cutters from 0.2mm would be very slow, due to the density of XPS. The first thing is done. The next step will be to build the mask frame assembly.

    Until next time.

     
    Last edited by a moderator: Nov 8, 2018
  6. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: New lifesize Giger Alien Version

    Hello everyone,
    the frame is almost finished. It remains to fix the graft by the tail.
    The next step is to cut the extruded polystyrene (XPS) based on the silhouettes of alien, and create the grooves to accommodate the frame. I thought I would do this by heating a tube and melt the polystyrene. If I use a tube smaller than that which will be hosted, I think the most accurate measure of jaundice. This method is faster and less strenuous manual cutter.

    See you next.

    TAVOLA PER TAGLIO POLISTIRENE ALIEN.jpg IMAG1433.jpg IMAG1434.jpg IMAG1435.jpg IMAG1436.jpg IMAG1437.jpg IMAG1438.jpg IMAG1439.jpg IMAG1440.jpg IMAG1442.jpg IMAG1443.jpg
     
  7. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: New lifesize Giger Alien Version

    Hello everyone,
    here is the full frame with graft tail.
    IMAG1444.jpg innesto coda.jpg

    This, however, is the support for comfortably operate on the bust when it is not mounted on the legs.
    IMAG1445.jpg SUPPORTO BUSTO.jpg
    See You Soon
     
    Leigh likes this.
  8. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: New lifesize Giger Alien Version

    Hello everyone,here is some progress. I cut the boundaries of the parts on transparent sheets,that will help me bring the details on polystyrene. I used a hot iron to make the channels that house the aluminum frame. Then I packed with glue the frame inside the panels. The electric cutter allowed me to cut the pack of glued panels,also in the lateral direction,putting under a thickness and two aluminum bars to equalize the discontinuous profile and to obtain orthogonal cuts. This is a bust and I will do the same for the other parts of the body. See you at the next progress. :)

    IMAG1450.jpg IMAG1452.jpg IMAG1453.jpg IMAG1463.jpg IMAG1455.jpg IMAG1460.jpg IMAG1464.jpg
     
    knnyjay and Leigh like this.
  9. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: New lifesize Giger Alien Version

    Alien wip...
    IMAG1477.jpg
    IMAG1478.jpg
    IMAG1479.jpg
     
    knnyjay and Leigh like this.
  10. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: New lifesize Giger Alien Version

    You don't hang about do you! :thumbsup :)
     
    daredevil665 likes this.
  11. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    here is some progress,some embroidered with tape.
    IMAG1481.jpg



    Today the department store I found these parts used to Giger alien. when I needed I found them not even cry. Today I do not need,I find an avalanche.
    IMAG1480.jpg
    is the fate that makes fun of me?:wacko
    I forgot, someone can give me a picture of the front of the skull Giger Alien. If that there are different versions,like that of Rambaldi,but I do not know which is the original Giger (possibly in front view) thanks.
    See You Soon
     
    Last edited: Jan 4, 2015
    knnyjay and Leigh like this.
  12. Clutch

    Clutch Master Member

    Trophy Points:
    3,336
    Re: The Eighth Passenger

    Looking good!
     
  13. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Thanks Clutch. :)

    This weekend I completed the fixing system of "exhausts" and the rear fin. In fact, even if it would be enough, would add little magnets that will block those small oscillations that may be moving the statue, caused by the small space between the square tubes (male / female). I also created a fastening arm, which is more complex, because the arm has two angles and most distances to be checked while making the fixing.

    See you next.

    IMAG1482.jpg IMAG1483.jpg IMAG1484.jpg IMAG1485.jpg IMAG1486.jpg IMAG1487.jpg IMAG1488.jpg IMAG1489.jpg IMAG1492.jpg IMAG1493.jpg IMAG1494.jpg
     
    Last edited: Jan 20, 2015
    knnyjay and Leigh like this.
  14. DAVIDYR1

    DAVIDYR1 Official Licensee RPF PREMIUM MEMBER

    Trophy Points:
    1,981
    Re: The Eighth Passenger

    Wow, another build? Loved the first one and can't wait to see this one too.

    David
     
  15. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    Excellent! :)
     
  16. Nial

    Nial Active Member

    Trophy Points:
    342
    Re: The Eighth Passenger

    Daredevil665 Wow just wow! I mean i thought the last one was amazing and you are already making another epic. Well done sir!
     
  17. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Thanks guys,
    Hello everyone,
    I would like to know your opinions about the fingers of the alien hand.
    In the film, the fingertips of the alien are joined, instead the model made by HR Giger, that I believe was used to get the molds, the tips are separated, as can be seen in the reproduction of Yoshihiko Sano. Like you the favorite? In your opinion, why they joined in the film? anyone knows their history about it?

    alien.jpg tumblr_lsgnnzwm6f1qaww4ro1_500.jpg alien1979directorscut10.jpg 302094-1.jpg
     
    knnyjay likes this.
  18. DAVIDYR1

    DAVIDYR1 Official Licensee RPF PREMIUM MEMBER

    Trophy Points:
    1,981
    Re: The Eighth Passenger

    They glued them together to give the actor the ability to move all 6 fingers, of course with his hand only in 5 'glove' fingers.
    Still, If you're asking for preferences, personally I prefer the glued fingers to the spread open hand. Feels right probably because they were like that on film. The on film and as seen on film is always my preference...but that's just me.
    Keep up the great work.

    David
     
    Leigh likes this.
  19. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    I agree with David "as on screen" looks best :) they also continued this idea with the alien from ALIENS. If it were up to me, I'd go with the stuck together fingers :)


    [​IMG]
     
    Last edited: Jan 22, 2015
  20. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    I too agree, even though I like them both. I think the look "Xenomorph" (xeno = unusual and morpho = form) befits better with a form that does not make sense in nature, because they are two separate fingers at the base but united in the tip. Never seen in nature. It might seem similar to the chameleon, but those of the chameleon are not formed by two fingers together. Then Alien is similar to the human, has a tail with sting like the scorpion, wove like a spider, comes from eggs like cockroaches, have exhausts on his back, and nerve fibers are exposed without skin and resembles death. Xenomorph is just one! :wacko

    Yesterday evening I had tacked the form, but I did not want to influence your choices.
    IMAG1495.jpg

    Thus, I needed to have greater peace of mind.

    Thank you very much participation.:):thumbsup
     
    Last edited: Jan 22, 2015
    knnyjay and Leigh like this.
  21. nick daring

    nick daring Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    2,455
    Re: The Eighth Passenger

    Woo hoo! Another Alien sculpt! Can't wait!
     
  22. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Thanks Nick. :)

    Hello everyone,
    I tried to make the teeth from a supplier which owns professional 3D printers. The material is ULTEM, incredibly hard and with excellent surface finish. He estimated the tail of ALIEN, 2.75 meters long, 400 €. I will spend more to make it manually, including material and labor, and not be completely accurate as rapid prototyping. I fear that we sculptors ended, unless we learn to sculpt on the computer?:wacko
    :unsure:confused

    [​IMG]
     

    Attached Files:

    knnyjay and Leigh like this.
  23. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    Awesome! :thumbsup but it looks sooo familiar ;)
     
  24. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Thanks Leigh, is, indeed, as always, you have inspired me, because if I want to make the molds of the jaw with teeth, it becomes more complicated and could not be good. So your method is the best. But this was also a test to see the quality of this technology, which in that area must be especially precise. Given the relatively low cost, I could replicate the entire jaw, using rapid prototyping, and make molds fiberglass only for larger volumes. :)

    This is the part above, made with two different materials and different printers: ULTEM with high mechanical properties and weighing over from professional printer; Corn extract from home printer.

    [​IMG]
     

    Attached Files:

    Last edited: Jan 29, 2015
    knnyjay and Leigh like this.
  25. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello everyone,
    here is the inner jaw. Failed of good quality, but I knew, for the settings of the 3D printer. However, sanding a bit ', I can improve them. These pieces are good for a dimensional and functional verification, but not for the definitive, for which will be made with 3d laser printer, or sintered.
    See you next :)

    [​IMG] [​IMG]
     

    Attached Files:

    knnyjay and Leigh like this.
  26. Nial

    Nial Active Member

    Trophy Points:
    342
    Re: The Eighth Passenger

    DareDevil nice to see you have come along some more since my last visit. The teeth and inner jaws look great. Just for me and i know i am a little late but i too agree with the other guys about the joined fingertips. I myself much prefer them joined. This creature is so unique and bizarre looking i just think they suit it better. But ultimately of course it's your sculpture and you must do what pleases you. great work.
     
  27. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger


    Thanks Nial of your participation,
    I'm doing tests to find the best value for money.
    Some quality can not be seen from the images, such as the strength, the weight and flexibility.
    I did make the entire tail, sintered. It is done in areas that fit through dovetail, with zero tolerance. Not even see the seam, except with the magnifying glass. It is amazing for the shape and definition, but it is too rigid. Handling it a little inexpertly may break. Then I could proceed in different ways, some of which are these:
    1) it totally by hand, as done previously, but I would avoid a lot of work even if the results are great for flexibility and robustness (and less expensive).
    2) do the sectors in rapid prototyping as the vertebrae of dinosaurs, to slip into an iron rod to give the curve, and keep them in line with references male-female.
    3) do rapid prototyping of the entire tail straight, and then make silicone molds to make the tail rubber, with drowned inside an iron rod to bend the tail at will. (the most expensive, but the most beautiful)

    Now I have not the pictures, because the parties are still displaced from the manufacturer.



    I'm trying to see if I can do the whole head, with movable jaws, rapid prototyping, but still I continue with the parallel street of the sculpture, which is always more exciting.
    The first thing to do is the mold for the transparent dome, which necessarily must be made in thermoformed. Just so you can adjust the differences of coupling between the head and the dome, which is with the CAD model with the sculpture.


    For the moment I attach a new proof of teeth-made PC-ABS. This is what I like the most, because it is strong and light. They are waiting for the release sintered. I'm filling the shelves of teeth. :)

    [​IMG]
    Greetings
     

    Attached Files:

  28. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    I lost a bit 'of time due to CAD modeling. Waiting for me to come for the parties, I enclose some pictures of the head progress, held together with tape. The shapes are provisional and will be amended or refined with polymer clay. I am waiting for the model made with rapid prototyping to create the mold matrix of transparent dome. This model is calculated without the expected thickness of 3mm of the dome. Will use this model to create two half-shells of glass fiber, in which particular synthetic gypsum to obtain a replica in extra-hard plaster, to achieve the dome thermoformed.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     

    Attached Files:

    Last edited: Mar 25, 2015
    DAVIDYR1 likes this.
  29. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    Looking real nice!! :thumbsup
     
  30. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    thanks Leigh,you're always a great support;). It is not yet time for the deta2ils,but curiosity prevails and I'm feeling a bit 'as it may be. This is the version eyebrows that I like the most, with the lower lip seems typical of dogs.
    [​IMG]
    [​IMG]
    [​IMG]
     

    Attached Files:

    Last edited: Mar 26, 2015
  31. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    I've found the lips to be particularly tricky to get anywhere near right, I think the biggest problem is that there were 3 different types used on the original.
    I ended up trying to achieve a look that captured features from all 3 types but then you also need to choose which features to use for best effect :wacko
    I'll be honest.... I'm still not 100% happy with mine but its nearly there :)

    Personally I'm not so sure about the frown! Having a frown gives him a personality....I don't think he's as scary with a personality, IMO he needs to show NO emotion!

    I'm not in any position to proceed with mine at moment so I'm very interested to see how your dome comes out. Your vac forming buck looks very similar to mine but you've included raised area's on the sides & ends, I shall be watching closely :)
     
  32. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Yes, in fact there are several versions of the front eyes, teeth and lips.
    Here are some:
    The_Alien_head_construction.JPG 0025.jpg m-025-A29.jpg Bolaji-Badejo-alien-01.jpg

    I too am looking for an intermediate form. I do not think I'll do the moving lips as you realized you were in the video (nice work), because at the time I did not want to work too. Maybe later, more relaxed, when the bulk of the work could be dedicated only to this. Therefore, in view of a movable jaw, I thought to a form of the lips that could agree on both positions, open and closed. Therefore lip relaxed, which is typical of the position "MUSEUM", although it is very nice, it would not be the most appropriate for this purpose. With regard to the increased volume of the dome mold, place immediately after the perimeter outside the figure, it is to facilitate the release of the polycarbonate. As regards the rim carved out, visible in the image zooming, it serves to mark the end of the figure, to mark the visibility during the cutting of the polycarbonate.
     
    Last edited: Apr 24, 2015
  33. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello everyone.
    Finally came the sintered parts that I need to proceed.
    The first is the model to achieve the two fiberglass parts (left and right), I need to get the same shape, but in synthetic gypsum extra hard> 300 Brinell. This is the model of the transparent dome,which must be a bit stuccoed here and there.

    IMAG1565.jpg IMAG1566.jpg IMAG1567.jpg IMAG1573.jpg IMAG1574.jpg

    The others are details of the head and jaw and mandible internal system. To these I will make the molds silicone rubber.
    Let me wishes, because my experience on the molds is zero! :wacko

    IMAG1569.jpg IMAG1570.jpg IMAG1571.jpg IMAG1572.jpg

    While waiting for these pieces, without which I could not proceed to finish the head, I carried on filling the rest of the body.

    But times are getting longer, because the spring it also takes a bit 'of the gym to prepare for the mountain bike in the nature !!! :)

    See you soon!
     
    Leigh likes this.
  34. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    I'm really looking forward to your updates especially regarding the dome! I'm keen to see how the vac forming comes out, I may have to alter mine here & there :)

    Excellent work so far :thumbsup
     
  35. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Dear Leigh,
    Thanks for your participation.
    To achieve this dome I had to find a compromise in the undercut, because in the previous ALIEN I had problems caused by strong undercut. The worker had to restrict the suction of the vacuum in the area of ​​the undercuts, closing the small holes of the intake (1.5mm diameter), with the consequent loss of curvature, not to break the dome during the extraction. So as not to lose all the bending, I decided to split it a little between the dome and the head, as seen in this image.

    [​IMG]
    Making the dome very thin, to have greater flexibility of plastic, it is very difficult, because the sheet departure remains constant in the thickness during the mold. Being the mold very long and high, the stretching is remarkable. I have considered to have 3mm thick in the coupling areas with the head, while in the center of the other part could be 1.5mm. In previous ALIEN, for 3mm, the worker went to a thickness of 5mm plate and had to pull it out when it was still hot, because the cold would be more difficult, with the risk of rupture.

    Below, we expose how will I get the mold itself.
    The sintered model you see in my previous comment corresponds to this image:

    [​IMG]

    On this model I am going to build a casting mold fiberglass, composed of two half shells, in which I will go to casting the synthetic gypsum to obtain the new robust model (25mm thick and 38kg).If the plaster mold should break, I can make another one because I have a fiberglass matrix.

    [​IMG] [​IMG] [​IMG]

    On this plaster model, I'm going to practice some holes, 1.5mm diameter, in the area of undercuts to increase the intake and adhere to the maximum thermoformed plastic model.

    See you next time.:)
     

    Attached Files:

    Last edited: Apr 24, 2015
  36. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    Nicely done!
    yeah, a row of evenly spaced 1.5-3.0mm holes drilled just under the perimeter tube area to create more suction in that area. I've been thinking along the same lines as you & the buck needs to be hollow to achieve this.
    As I'm skint at the moment I'll let you go first :D
     
  37. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello everyone,
    work is progressing slowly due to the summer passions. 1145537045-Sport26.gif

    These days I have fixed the system of rotation of the mandible. It consists of aluminum pins of 8mm diameter which rotate in aluminum tubes, inserted in the cheekbone area. Probably I put a small magnet to keep closed the jaw, or a spring that, beyond a certain point of rotation, can pull both opening and closing. In addition, small tires stop, to be seen whether or not the register stop.




    IMAG1596.jpg

    See you next :)
     

    Attached Files:

    Last edited by a moderator: Nov 8, 2018
    The Terminator, DAVIDYR1 and Leigh like this.
  38. Nial

    Nial Active Member

    Trophy Points:
    342
    Re: The Eighth Passenger

    Wow man it's been a while since i got on here to see how he's going and he is really going well. The video is greatly appreciated to be able to have a better look than just photos. Jaw movement is great and really smooth. Keep at it my friend he is looking awesome.
     
  39. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Thanks Nial,
    I'm restarting work after the holidays.
    Now I should start with the realization of fiberglass molds.
    I'll start with that to create the transparent dome.
    I have to create empty volumes for pouring the synthetic gypsum, so that, after pouring and having removed these volumes, will remain interior walls with rib feature.
    [​IMG]

    [​IMG]

    [​IMG]

    see you soon
     

    Attached Files:

    Leigh likes this.
  40. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello everyone,
    here is the modeling of the volumes to be extracted to obtain the ribs in the mold for the transparent dome.

    I probably will not have to finish them superficially, as it will clothe with Domopak aluminum to extract them easily, but I will simply reinforce them with a few rounds of tape.

    See you next

    IMAG1761.jpg IMAG1762.jpg IMAG1763.jpg IMAG1764.jpg IMAG1765.jpg IMAG1766.jpg IMAG1768.jpg IMAG1769.jpg IMAG1770.jpg IMAG1771.jpg IMAG1772.jpg IMAG1773.jpg IMAG1773.jpg IMAG1774.jpg
     
    Leigh likes this.
  41. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello to all, Here I basted the frame to make the first half of the mold in fiberglass.

    IMAG1779.jpg
    IMAG1781.jpg
    IMAG1782.jpg
    IMAG1783.jpg
     
    Leigh likes this.
  42. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello to all, To this mold not use silicone rubber. Use only fiberglass,because there are no undercuts. I plasticized with spray the separation area in MDF. So the wax for the posting will not be absorbed by the MDF. The black curve drawn on MDF,represents the limit of the lip which contains the keys coupling between the two shells of the mold. It is about 5 cm from the model. The keys are between them about 10 cm. The keys are made of stucco glass. I wanted to ask two pieces of information to those in the know:

    Are sufficient 5 cm (2 inches) of lip coupling?

    Sufficient number of keys stored in the picture?

    If you notice anything that might be wrong or not work,I'd be glad to hear it.

    Thank you in advance.

    See you soon.

    IMAG1786.jpg
    IMAG1785.jpg
     
  43. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello to all,
    Here are the two half-shells made of fiberglass. I had never worked with fiberglass and now I can say I do not like, and I can realize the hard work that awaits me, if I want to do all the molds. However the result is satisfactory. To know how much gypsum and how much water will be used to get the printout, I combined the two half-shells with volumes polystyrene and I filled water that I later weighed. Knowing that one kg of gypsum is combined with 250 g of water and that the mixture occupies a volume of 0.6 liters, I know how much gypsum and how much water is used. The total volume is 29 liters, thus serving about 48 kg of gypsum and 12 lt of water. A small problem I found when I filled with water, was the infiltration of water into the coupling area. To avoid this problem, I thought to seal with wax.

    the polyvinol
    IMAG1788.jpg IMAG1790.jpg
    the wax
    IMAG1792.jpg
    the gel-coats
    IMAG1793.jpg IMAG1795.jpg
    the shells
    IMAG1800.jpg IMAG1801.jpg IMAG1802.jpg IMAG1799.jpg
     
    Leigh likes this.
  44. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    Nice job! Neat & tidy :thumbsup :)
     
  45. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Thanks Leigh,
    here's the casting. The area is already very precise and clean, but I will have to remove the burrs in the middle and on the edges of the base. Some areas seem to have bent, but in reality are only spots derived from the mold, maybe it is just a little wax residue. Then I will have to polish the area useful and paste a wooden support to protect the edges of the base while dragging on the thermoforming machine.

    It was tough because I was alone to carry out maneuvers. They were required 48 kg of plaster and 13.5 of water, distributed in three buckets from the weight of 20.5 kg each, to mix in a short time 2-3 minutes each, in order to have a three buckets with the same viscosity. I failed to fully dissolve all lumps of chalk. Perhaps it would be better to make a bucket at a time, ensuring better mixing. However when no bubbles or surface areas mealy.

    This synthetic gypsum acquire its maximum mechanical characteristics (hardness> 300 Brinell) in 8 hours in the oven at 40 °, but in my case within 3 - 4 days at room temperature. However, it is already very hard and allows free sanding knead the sandpaper.

    Post back to the mold completed.

    Greetings

    IMAG1806.jpg IMAG1807.jpg IMAG1809.jpg IMAG1810.jpg IMAG1811.jpg IMAG1812.jpg

    These could be silicone residues, however, they are the alien skin residue moulting. :)
    IMAG1813.jpg
     
    Leigh and DAVIDYR1 like this.
  46. BatFastard

    BatFastard New Member

    Trophy Points:
    17
    Re: The Eighth Passenger

    I am totally Blown Away by your skills! Seriously, I can't believe how quickly you do this either!
     
  47. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Thanks BatFastard,
    I try, but I'm afraid it will be hard to complete the work.
    However, here is the finished mold and polished. The polishing is not only necessary for a better finish of the molded part, but also to improve the extraction of the piece, because it glides better with less friction. And in this case it is necessary that slides better, because there are some undercuts.
    I used an abrasive paste for car body with cloth and "gravy elbow" (way of saying fatigue) :)
    This evening I deliver it to the supplier of thermoformed and hope that it works well.

    Another point that I can recommend to those who want to do the same thing, is to keep a thickness less than that given by me, that is 25mm, because my mold weighs almost 50 kg. Should be more than enough 15mm, provided that it is ribbed like mine. You should get a mold from 30 kg.

    I return to post as soon as I got the first mold.

    See you soon

    IMAG1814.jpg IMAG1820.jpg IMAG1824.jpg IMAG1828.jpg IMAG1830.jpg IMAG1832.jpg IMAG1833.jpg IMAG1835.jpg IMAG1836.jpg
     
    Last edited: Sep 1, 2015
    Leigh likes this.
  48. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    This is looking really impressive!!! :thumbsup
    You've put a lot of hard work into this, I can't wait to see the results! :)
     
  49. Leigh

    Leigh Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,830
    Re: The Eighth Passenger

    Any progress on this? :)
     
  50. daredevil665

    daredevil665 Well-Known Member

    Trophy Points:
    935
    Re: The Eighth Passenger

    Hello Leigh, :)

    I'm waiting for the thermoformed piece. The supplier is overworked. Perhaps he will be able to give it to me next week and post the photos here. When I have the dome,I can finish the head according to the contours of the dome.

    Meanwhile,I have covered other parts of the body with plastic resin two-component "DURALOID COATPLAST",to protect the polystyrene from fiberglass.

    Thanks for your participation and best regards :)
     
    Leigh likes this.

Share This Page