I decided I needed to upgrade my IM costume, and foam seems the way to go. I've been lurking here for a month or so, and researching all else I can find on this method. (Thanks to all the people in whose footsteps I'm following.) I'm using the files from Robo3687, as well as the glue sealing method on "The Hero Turorials" on youtube. Then I'm going with the "smooth-cast 65D" method from xrobots.co.uk to make the suit look better and last longer, as I'm going to be using this for several years, I hope. I know that there are plenty of threads for this build, but what I'm posting, as I haven't found it, is what I'm learning as I build each piece, so that others can save time and energy.
I'll be working from the bottom up, and so far I've used the default size in the files, because they seemed to fit my 6'0", 200 lb frame.
As of now, I've assembled one boot, and it seems just a little short in length, and the mouth of it is a little tight to squeeze through. (I wear a size 10-11.) However, I'm not worried, as it's not too big a difference, and I've just ordered a hot wire foam cutter, so I'll use that to widen the necessary dimensions.
Here are the pieces I regret doing the way I did, and what I would have/will do differently next time.
Hope this helps any who are looking to start their first foam build. I'm learning more with every line of glue, so I'll post here with each bit of progress I make. I have pictures, but I don't have time to post right now. Soon!
I'll be working from the bottom up, and so far I've used the default size in the files, because they seemed to fit my 6'0", 200 lb frame.
As of now, I've assembled one boot, and it seems just a little short in length, and the mouth of it is a little tight to squeeze through. (I wear a size 10-11.) However, I'm not worried, as it's not too big a difference, and I've just ordered a hot wire foam cutter, so I'll use that to widen the necessary dimensions.
Here are the pieces I regret doing the way I did, and what I would have/will do differently next time.
- I didn't use the pieces for the heel treads (long, thin rectangles), or the thin pieces on either side of what would be the tongue.
- In the files, there's a shape like a flat-top "A", and between it's legs is a rectangle. I wish I didn't cut the rectangle as instructed, but rather used the larger outline, because then I could have wedged the piece in rather than faking it like I did.
- The crescent shape that makes the toe of the main boot seems useless, and I won't be building it into my second boot.
- Finally, the heel treads have a rounded inside edge, and I think it would have been much easier to cut them square.
- Once I figured out what angles needed to be cut into which edges of each piece to get the general angles and orientation right, I pinned the pieces together with "T" pins (I think they're also called hat pins, but straight pins would work fine.) This helped me see what shape I'd be getting without actually gluing everything down.
- When ready to glue, I tacked a little between the connecting surfaces, then reinforced with weld-like lines of glue on inside (concave) corners, inside or outside the boot.
- To get gentler angles, not quite curves, but not harsh seams, I cut wedges out of the inside, put in glue, and held it.
Hope this helps any who are looking to start their first foam build. I'm learning more with every line of glue, so I'll post here with each bit of progress I make. I have pictures, but I don't have time to post right now. Soon!
