First Molding/Casting Project - Stargate Jaffa Armor (from screen used pieces)

[TerryMcIntosh]

Hello, all!

Well, the time has come that I'm going to dive in to the world of replica casting and molding. My first item is going to be a Stargate Jaffa shin guard armor piece. Today I received my third complete screen-used Jaffa costume w/COA from the nice folks involved with Propworx and included with it were two brand new and never used shin guards. I've attached a quick iPhone photo of the least pristine of the two (just personal nit-picky stuff), which is still showroom fresh and amazing, that will be used for this first attempt.

Based on the massive amount of info that I have gathered from reading posts on The RPF, as well as various YouTube videos from professionals and other hobbyists, here's my plan of attack on the subject:

- Create a box shape on a perfectly flat board, or piece of thick plexi, that will contain the original piece and form the mold walls
- Insert piece in to mold-to-be's area, beauty side up (since they're only finished on one side of the piece from production), and strategically pin down the item to be perfectly flat
- Spray on a release coat so that the silicone doesn't damage the original paint (still researching this)
- Add silicone to mold using the best methods I've been able to determine to reduce the chance of bubbles and let cure (still researching the type of silicone to use, but at this moment I'm aiming for PlatSil 71)
- Remove walls, flip over and remove original piece -- if all goes well there will be a great mold
- Add liquid rubber compound to mold, smoothing out the back to be as even and flat as possible and maintaining the thickness of the original piece -- I'm aiming for Poly PT 85 since it's strong (from what I've seen, but also bendy which this piece requires) and let cure
- Remove new shin guard from mold and if all goes well then paint to production colors which I've already mostly matched
- Reinforce edge areas where lace holes will go with additional layers of a stronger liquid rubber and let cure -- if I get fancy someday perhaps even add some kind of thin metal or plastic in to the cast structure along those edges for extra reinforcement before the holes are drilled. If I get really fancy, or find out that it's needed for structural integrity, then I'll work out some sort of internal nylon inner structure that will be sandwiched in to the mold and then be covered with the rubber on the front and back sides. This is all new to me and I'm not afraid to spend the money to experiment with different materials in order to get the best possible end result.
- Add a painted leather piece for the boot cover flap that is attached from the back side like the original piece
- Add a nice felt backing to the piece to cover the non-business side and secure with hot glue like the original piece has
- Enjoy a tasty adult beverage to celebrate

If all goes well then I may even consider a run of these if there is interest from folks and the legality/ethics of doing such a thing is explored (I'm new, so I don't really know). And if all really goes well then I'll begin to tackle the other pieces of the costume -- wrist guards, belt and buckle, and finally the most complex piece of all which is the collar that is made of multiple pieces and glued together. In any case, I'll be posting step-by-step photos and possibly even a video or two to document the experience for others that might want to get in to this. I'll be ordering the materials in the next few days, so I should have something progress related to post as early as next week.

Feedback and suggestions are strongly encouraged, and keep your fingers crossed that I come out of the other side of this adventure with all fingers and both of my eyebrows intact! Thanks for checking out this experiment in progress.

Best,

Terry

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

A quick update:

My molding and casting materials have finally arrived (boy, that UPS delivery man sure got a workout bringing the box to the door) and I'm hoping to begin the project by making the first silicone molding box later this week. Hey, this first attempt is on a largely flat object, so what could go wrong, right? *fingers crossed*

Stay tuned!

 

[kwalsh0000]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Best of luck with it later. The first time is always nerve wrecking but will be fine once you have nice walls, fully sealed so no leaks and either pour it from a height and one corner to let it flow over without bubbles or best to even use a brush on layer first to make sure theres no bubbles. Oh and make sure to just mix enough catalyst and mix it well and you will be laughing!

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Best of luck with it later. The first time is always nerve wrecking but will be fine once you have nice walls, fully sealed so no leaks and either pour it from a height and one corner to let it flow over without bubbles or best to even use a brush on layer first to make sure theres no bubbles. Oh and make sure to just mix enough catalyst and mix it well and you will be laughing!

Thanks for the tips! Yeah, I've watched hours of video online on the subject and can guarantee that I've over analyzed it to death. So, it's time to just release a few PSI from the built-up butt pucker, take a deep breath, and go for it. =P I think I'll first mold something benign, like a small painted rubber toy from the local shop, before I toss an irreplaceable prop item in to the fire (so to speak).

... happy place... happy place. =)

 

[Snarkticon]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Just stumbled upon this thread. I'll be watching with great interest as I'm considering a Jaffa costume sometime in the near future.

 

[TheDarkPope]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Are you able to de-gas your Platsil? If not, there's a video on Smooth-On's website on how to pour if you don't have a vacuum chamber. You'll still get bubbles, but the method they show will help lots in not getting big bubbles. It basically involves using height to your advantage. Pour a thin stream from 100 feet above your mold (ok not that far) and the thin stream will reduce large bubbles. Play with a few ounces before doing your big pour. It'll help you get the feel for it. I've never used 71, but I do use gel-10 and gel-00. When I first started, I used a gram scale to measure 20 grams each A & B and mixed just to see how it mixed, how it poured, what curing times were (even though the're peinted on the label), how it reacted differently if I used deadener, or thickener. That playing saved me a lot of time and money later, as I knew what I was getting myself into.

You might want to check out The Effects Lab also. Lots of seasoned professionals in the special effects biz that answer questions all day long about Platsil.

TheEffectsLab

Good Luck!

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Are you able to de-gas your Platsil? If not, there's a video on Smooth-On's website on how to pour if you don't have a vacuum chamber. You'll still get bubbles, but the method they show will help lots in not getting big bubbles. It basically involves using height to your advantage. Pour a thin stream from 100 feet above your mold (ok not that far) and the thin stream will reduce large bubbles. Play with a few ounces before doing your big pour. It'll help you get the feel for it. I've never used 71, but I do use gel-10 and gel-00. When I first started, I used a gram scale to measure 20 grams each A & B and mixed just to see how it mixed, how it poured, what curing times were (even though the're peinted on the label), how it reacted differently if I used deadener, or thickener. That playing saved me a lot of time and money later, as I knew what I was getting myself into.

You might want to check out The Effects Lab also. Lots of seasoned professionals in the special effects biz that answer questions all day long about Platsil.

TheEffectsLab

Good Luck!

Thanks for your note. Yes, picked up a small degassing chamber, and will be using Smooth-On's products (thankfully they have a distributor in my state which really cut down on the shipping costs). I haven't opened the chamber from the box yet since I want to try the method that you mentioned where proper technique could be used instead. I'm hoping to learn all of this strictly for fun, and don't mind screwing up a few times, especially since I went a little crazy with ordering the silicone and rubber ingredients in big buckets, so trial and error to learn about the properties and best practices has been planned in to this. I'm still unboxing all of the accessory items, like the gram scale for ingredient measurement, glue gun for mold wall sealing, release agents, airbrush system, highest quality paint brushes for certain detail work, and all of that other fun stuff that was on the laundry list to get this new interest off of the ground.

I have to tell ya, I haven't been this in to a new hobby in a long time, so hopefully with patience and a bit of practice things will turn out well. I'm rather a perfectionist, so if I manage to be able to cast excellent quality items then I hope to be able to help others in their collecting/costuming by offering castings of original items that I own to other fans strictly for the fun of it. I'm passionate about the Stargate franchise, so where better to start than at something that you care about doing right by?

I will certainly try as you suggest and thank you for taking the time to offer those wonderful suggestions. I'm sure your advice will hit the mark with a little trial and error when moving from theory to practice on my part. I still think that I should ring up Lloyds of London and insure the eyebrows... aren't those usually the first casualty in a new hobby that involves chemicals? =)

Best,

Terry

 

[TheDarkPope]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

One more thing before I forget...

I don't konw about 71, but I'm assuming it to be the same as 10 and 00 - don't use latex gloves, latex anything on, in, around, or near your Platsil. It won't cure right, if at all, if latex is introduced. Use nitrile gloves if you need gloves.

If you're using clay, make sure it isn't sulphur based or curing will be screwed. Chavant NSP or some other non-sulphur clay will be your best bet.

If you have a wickedly good and strong air compressor already (don't we all?), you can do poor man's de-gassing. A 5 gallon bucket, a strong plexiglass lid, air compressor, some hoses and one of these...

Advanced Tool Design Model ATD-3410 Air Operated Vacuum Pump : Amazon.com : Automotive

can (not always) get your stuff bubble free. Your compressor needs to be able to pump out 120 or so psi constantly for this to work. I can't remember what the cubic feet per minute # is for the compressor to make this work - but it's a lot.

Once again - have fun.

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Thank you for saving me a bad batch with the glove tip. All I ordered were latex, so on your suggestion I'll be sure to order the recommended brand immediately!

Yes, I got the NSP clay specifically -- a huge frickin block of it just sitting on my new hobby table as a matter of fact. Hopefully it doesn't dry out too quickly if kept well sealed, but if it looks like it may then I may have to try my hand at molding all of the pieces first before casting, just to burn through the clay. As much as that stuff weighs, it almost cost more to ship it than the asking price of the materials, but I'm sure there are suppliers here locally if I looked a bit harder. =P

One thing that hampers my ability to really go crazy with this new hobby is that I'm a condo dweller, so I've converted one of my spare bedrooms for the effort. I created a filtered exhaust system, in case it's needed depending on the materials that might warrant such a thing, that I can pop in to the window, clamp it down, and then fire it up. But, unless I could find a quiet compressor, the neighbors would have my head on a pike. I'll see how loud this dinky little one I ordered will do if I decide to try degassing after trying the 'by technique' method. What I had seen in some videos is instead of degassing, you do the slow and high pour in to the mold and then use compressed air to blow over the wet silicone a few times as it cures and that, theoretically, removes most bubbles. We'll see. It might be a disaster, but I'll give it a solid try.

Thanks again for your suggestions and I'll be sure to give them a try to see how they work in my case (and whether I can pull them off)!

Best,

Terry

 

[cyberpred]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

I remember the good ole days when all you could see in the air was cabosil.

I had molds everywhere. My degass was a suction pump and a glass dome.

Good memories.

C.

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

I wish I had made the decision to try my hand at all of this years ago, because the sticker shock of the materials needed these days is pretty hard core. I've already dropped well over a grand and am still waiting for some components to be delivered. Time to crack the whip on UPS and hopefully the remaining bits will show up either today or tomorrow so I can get this project off of the ground!

Let the silicone flow! =P

 

[NormanF]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

This is probably too late, but the local home improvement or auto parts stores will carry nitrile gloves. As for the rubber, I have specifically gone for the stuff that does not have to be degassed: First Oomoo 30 and now MoldStar (they really pushed this stuff at a seminar I went to). I could see a lot of bubbles in the MoldStar, but none of them were on the face that the resin contacts. I would like to get a vacuum system at some point though. But like you said, $$$.

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Thanks for your post, NormanF. Yeah, got the nitrile gloves here locally, along with some other items, like Oomoo 30, from a local art supply store. UPS did show up today and delivered the "A & B" bottles of the rubber for these shin guards, and now I'm waiting for the degassing pump to arrive, along with another huge block of sulfur-free clay. Once those land on my doorstep then I'll get to molding. My spare bedroom has been completely converted to make all of this happen -- like they say, if you're going to do something, go all out! =)

 

[jv4779]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Having also recently started getting the stuff to do castings the money outlay sucks. But decided at the start there was no reason to go cheap and make it even harder to get good results. Best to take some variables out of the learning process.

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Having also recently started getting the stuff to do castings the money outlay sucks. But decided at the start there was no reason to go cheap and make it even harder to get good results. Best to take some variables out of the learning process.

I agree with you completely, jv4779. If you're going to do something then might as well do the best possible job, even if there's a bit of a sticker shock! =)

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Just a quick note to let folks know that this project is now in progress and my first ever attempt at silicone casting is now solidifying as I type this. I've decided to mold the belt buckle first since it's smaller and if I totally botch this first attempt then the mistake won't be as costly due to wasted materials. If all looks good when I de-mold the original piece in the morning then I'll rebuild the mold walls and I'll drop the silicone over the shin guard and start the stop watch for curing time.

If all goes well, and the new gallon of silicone chems that I've ordered arrives on Tuesday or Wednesday, then I'll get to molding the wrist bracers, belt, and shoulder piece as well. *fingers crossed* Then the fun will begin... painting the pieces to be as exact as possible to the original screen-used pieces and knock out a complete first set of armor. I've tracked down perfectly matched paint colors that duplicate the original pieces, including the metal powder to load in to the molds when casting as that appears to be a component of the originals as well. If that also goes well then I'll consider starting a run if there's interest.

I must admit that I'm terribly excited to have finally made the time to get in to molding and casting as it's been something that has fascinated me for a great many years.

Happy Labor Day holiday extended weekend to those in the US, and my best to those who are not for a wonderful weekend, too!

Best,

Terry

 

[Snarkticon]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Great news, Terry! I hope the mold of the buckle turns out well. I've botched up a mold or two in my time and it's alwyas irritating. Incidentally, are you planning to sell only finished pieces? Or will you als be selling raw casts in "kits" for people to finish on their own?

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Great news, Terry! I hope the mold of the buckle turns out well. I've botched up a mold or two in my time and it's alwyas irritating. Incidentally, are you planning to sell only finished pieces? Or will you als be selling raw casts in "kits" for people to finish on their own?

Thanks, Snarkticon. I can confirm that the first mold of the belt buckle has turned out perfectly -- not so much as a micro-bubble that I can detect with a magnifying glass -- so today I'll keep making molds until I run out of the silicone that's on hand. Once I run out then work will resume again later in the week when the new order of materials is delivered by UPS. The final piece to have its mold made will be the shoulder piece, since that's going to be complex and really take some extra special attention due to the size and multiple surface nature.

To answer your question, I don't see any reason why offering non-painted versions would be a problem, so sure, why not. Once I have the first set cast and trimmed, I'll sit down and work out the math on actual expenses to make a kit and then come up with a fair price that covers costs for materials and a modest margin for the effort.

Best,

Terry

 

[Snarkticon]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Excellent. I'll be watching this thread with great interest since my brother and I are wanting to make Jaffa costumes.

 

[TerryMcIntosh]

Re: First Molding/Casting Project - Stargate Jaffa Shin Guard Armor Piece

Here's a few iPhone photos of the first finished product. The mold is Smooth-On silicone and the rubber is PT-Flex 85, although I'm going to go with PT-Flex 60 for the run, since it's a bit more bendy like the original. My goal here is to make the casts as close as is possible to the originals and that means getting the rubber as exact as possible as well.

Inside this first try is thin burlap that has been cut just shy of the edges in the shape of the piece, just as the originals are constructed, and holding the newly cast piece up to the original piece shows every last minute detail which is exactly how I had planned.

The first photo is the mold solidifying. The second photo is the original pulled from the mold. The third photo is of the first trimmed rubber cast.

Now to get to the shin guard and wrist gauntlets!