First Prop Build. The Holy Grail!

Discussion in 'Replica Props' started by jedichase, Jan 8, 2012.

  1. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Hey everybody.

    I've been a reader on here for while and I finally got the tools, knowledge, and confidence to start my first prop build. I have chosen the holy grail from Last Crusade as my first prop because its simple yet iconic. I'll be making it out of wood on a wood lathe.

    I'm going to be building the hero grail instead of the slightly wonky elsa grail. After doing a ton of research I found some dimensions of the hero grail and drew a sketch of it. Here are a couple of pics of my sketch (sorry for the large size) and the grail I'll be replicating.
    [​IMG]
    [​IMG]

    How does the drawing compare to the screencap? I'm not 100% confident on how I'll dig out the cup on the lathe, so any info will be much appreciated. If there is any interest in this prop I might make 5 of them to trade. Thanks for reading.
     
  2. Rassilon

    Rassilon Well-Known Member

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    I just love design drawing concepts, I start my designs out the same way, by drawing them on paper, and then converting the design sketch into CAD 3D modelling, Oh make sure you post some pic’s of your work on the wood lathe, love action shots as well, that’s a good start on your holy grail project.

    What type of wood will you be using for the Grail?
     
  3. Maelstrom

    Maelstrom Sr Member

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    Watch this vid. Should give you some idea. Your one end is going to be chucked rather than on the pivot point

    Woodturning Projects Egg Cup - YouTube
     
  4. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Maelstrom: Thanks for the video. I'm a little more confident now. I'll have to get a four jaw chuck for my lathe.

    Rassilon1: I'll most definitively be putting pics up as I go along. For the wood I might use hickory or some other wood that is denser than most common woods.
     
  5. TazVader

    TazVader Sr Member

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    I did a run of these when I first started as well mate. Way back when. I remember selling them for $70 usd a pop at the time. I think a few folk still have them. lol Looking forward to seeing how you do. Any help at all feel free to pm me. Also with the paintup. I think that was the best part.

    Best
    Taz
     
  6. jimjimmyjones85

    jimjimmyjones85 Active Member

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    I would be interested. Especially if the price is right !
     
  7. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Thanks for the support.

    So far I have everything I need to start (lathe, chisels) but I can't find any good quality wood that is 6x6. Everything I'm finding is cracked pine. My father (a tile layer) knows a carpenter that might be able to hook me up with the proper wood. So hopefully I can get started on this by the end of the week.
     
  8. Idaho Jones

    Idaho Jones Well-Known Member

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    I created my block by gluing up several layers of wood.

    Heres a pic showing the layers, altho I hand carved mine with a belt sander and a dremel
    [​IMG]
     
    Last edited: Jan 10, 2012
  9. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Thanks for the info Idaho Jones. This sounds like a more logical solution.
     
  10. moviebuff5

    moviebuff5 Well-Known Member

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    If you want solid wood, look for turning blanks. You will probably need to go to a specialty store like Rockler, Woodworkers Source, or Woodcraft. Rockler and Woodcraft are national chains, and all three have websites.
     
  11. Maelstrom

    Maelstrom Sr Member

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    That is beautiful work for a belt sander/dremel combo! Would have sworn it was lathed.
     
  12. TazVader

    TazVader Sr Member

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    Look on ebay....you can find turning blanks there:)

    Best
    TAZ
     
  13. Idaho Jones

    Idaho Jones Well-Known Member

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    Thanks. Getto prop making, using material and tools you have:thumbsup
     
  14. charlie_k

    charlie_k New Member

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    Looking good mate, I will be waiting for the finished version.
     
  15. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Thanks for all of the support.

    I think my best option on both money and time is to follow Idaho Jones' technique of glueing boards together to make my block. I'll have to pick this up as well as paint on my next trip to Lowes. Thanks again for all of the encouragement.
     
  16. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    I've got good news and bad news.

    Good news: I solved my wood problem. My father is good friends with a carpenter who is giving me some scrap African Mahogany! I'll have to get the wood in a couple of days. Needless to say these cups should turn out to be beautiful.

    Bad news: I just did my first try at woodturning with some scrap oak. As I was working the motor began to overheat! Mind you that I borrowed the lathe from my grandfather who hadn't used the lathe yet and was not aware of any problems. So I'll have to replace the electric motor.

    Although there are snags I'm still pursuing my goal.
     
  17. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    I finally got the wood! :) The mahogany looks beautiful. I have my first block (which will make 3 cups) glued up and now I'm letting it dry.

    I also got a replacement motor for my lathe. Though it has less horsepower it will work for my project.

    I'll post some pics of the wood blocks tomorrow.
     
  18. Idaho Jones

    Idaho Jones Well-Known Member

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    Looking forward to it, good luck!
     
  19. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Hey everybody,

    Didn't get a lot of progress done today since I spent most of the day at a Flea Market (I didn't find anything there). But I did cut my first 3 blocks. Tomorrow I'll run them through the table saw to get the proper width, and maybe start turning them. Here's a couple pics of the blocks and wood.
     
  20. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    I finally got to turn the stems of the first 3 cups and finished shaping 1 cup! I'll get some pictures up as soon as I can get my sister to email them to me.
     
  21. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Re: First Prop Build. The Holy Grail! Progress pics.

    Finally some pics.
    First, is the 3 cups in which I completed the stems. On the far left cup I dug into the stem a little to deep so I'll have to fill it in with wood filler.
    [​IMG]
    Second is a photo of the first completed cup. I still have to carve out the inner bowl but that'll wait.
    [​IMG]

    What do you guys think? All of the imperfections will be fixed with wood filler.
    Thanks for reading.
     
  22. Idaho Jones

    Idaho Jones Well-Known Member

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    Very nice :thumbsup good effort. What are your plans for finishing them?
     
  23. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Thanks for the support Idaho Jones,

    Once I get all of the lathe work done for the 6 cups, I'll then use a bondo-like filler made for wood to remove the wood grain and fix any details I couldn't get with the lathe. Next, I'll paint it with a terracotta colored primer that I found and then gold leaf the cups. After that I'll weather the cups and put them up in the junkyard.
     
  24. jedichase

    jedichase Well-Known Member RPF PREMIUM MEMBER

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    Finally got some progress. Between high school, college, and work; I haven't had a lot of time to work on these.
    Anyway, here is a picture of the status of all 6 of the cups. I still have a cup and a half to go to finish the exteriors.

    [​IMG]


    Digging out the inside of the bowls is going to be difficult, but I think I'm going to find a large drill bit and drill out the centers to get rid of some of the top heaviness. Then I'll finish shaping them on the lathe.
    What do you think so far?
     
  25. Idaho Jones

    Idaho Jones Well-Known Member

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    Nice job they look great! Now get to painting.:thumbsup
     
  26. MooMooEgg

    MooMooEgg Sr Member

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    looking great! :thumbsup
     

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