Foam Sculpting My First Bio - Beyond The Final Rung

[JehdinThwei]

Sweeeeeet!!!!!  The lenses look great installed.  Very very cool pushrod for the switch!

 

[AlphaTech686]

O, I see the 3 blade thing up there. Dude I really like the tricked out push button. Very inventive and none human.

 

[REYALS1]

This is more and more becoming a masterpiece in it's own right. 

I'm am completely floored by the passion and commitment that is going into this beauty. I mean, every time I turn around and a new updated post is made... it is just mind boggling at the extent of progress that is made. This has to be the most extensive Bio thread on here in terms of modification and application. 

Truly inspiring.

 

[BonzRus]

Sweeeeeet!!!!!  The lenses look great installed.  Very very cool pushrod for the switch!

Thank you. I think they turned out OK. I am not totally satisfied with the job I did installing them but I know what to do to make it better next time.

O, I see the 3 blade thing up there. Dude I really like the tricked out push button. Very inventive and none human.

Hey Jeff, thanks...I wanted to utilize the arm like thing as it appeared in the drawing for that purpose initially so I created it to pivot but honestly wasn't sure how to install the micro-switch until I got to looking at it and had the battery holder in place. Then it just kinda' made sense and things lined up right. It works great.

This is more and more becoming a masterpiece in it's own right. 

I'm am completely floored by the passion and commitment that is going into this beauty. I mean, every time I turn around and a new updated post is made... it is just mind boggling at the extent of progress that is made. This has to be the most extensive Bio thread on here in terms of modification and application. 

Truly inspiring.

Thank you very much Ricky! You are always such an encouragement to me. This is something that I truely enjoy doing so I am glad that it shows. Building this bio has been a learning experience for me and I have learned so much along the way...especially with the help of everyone who has gone before me and created threads of their work here on the Lair or who have taken the time to chime in and offer support or ideas like yourself. There are things I would do differently to improve it, things I would not do or use again and I have been challenged with materials and methods I have never used before, etc. My greatest desire though is to see God be glorified through the gifts and skills He has given me so I strive for those things that would do that. Quality, integrity, diligence, honesty to name a few. So yes, I have a passion for this. Again, thank you for the kind words.

Steve

 

[Double H]

Wooooh! That is simply awesome, another rung reached. Gotta get one of your ladders bud the push button is a smashing and innovative idea

 

[wonko]

The finishing touches are really setting this apart from the average run of the mill bio Steve.  The thought and planning you put into this are a big part of why I'm so awe-struck by this piece of art.  I hate the thought of having to wait another week to see this finished, but you're right...now is not the time to cut corners (like you would do that anyway   ).  You truly have been blessed with some amazing gifts and talent, and it's AWESOME that you're sharing it with all of us.  I'll wait patiently (or not  ) for the final product!

Brian

 

[BonzRus]

Wooooh! That is simply awesome, another rung reached. Gotta get one of your ladders bud the push button is a smashing and innovative idea

Thanks! It was one of those ideas that just "fell into place" at the right time.

The finishing touches are really setting this apart from the average run of the mill bio Steve.  The thought and planning you put into this are a big part of why I'm so awe-struck by this piece of art.  I hate the thought of having to wait another week to see this finished, but you're right...now is not the time to cut corners (like you would do that anyway   ).  You truly have been blessed with some amazing gifts and talent, and it's AWESOME that you're sharing it with all of us.  I'll wait patiently (or not  ) for the final product!

Brian

Thank you Bryan...your encouragement helps keep me moving forward, I really really appreciate it. Almost there.

Minor update:

I spent some time last night working on the "next rung"...  Sorry, but I am not quite ready to post on that just yet. I have ordered a few of the tools I will need to complete this piece and I powered up the lasers I orderd and they look like they will work great! I plan on spending some time playing with the leather by testing some different embossing methods to see what tools and materials will work to accomplish the look I am after. Sorry, no pictures today but I hope the "next rung" with make up for it very soon. 

Steve

 

[evilpred]

Wow Im blown away by the work and detail that went in to do this !!! Awesome dude

 

[Eaglewood]

Quivering with excitement here---- Not really but I am anxious to see what you can do to top what you have already done.  A true craftsman Steve.

 

[BonzRus]

Wow Im blown away by the work and detail that went in to do this !!! Awesome dude

Thank you very much!

Quivering with excitement here---- Not really but I am anxious to see what you can do to top what you have already done.  A true craftsman Steve.

Thank you Clay. I hope the leather goes well as I have never worked with leather before...but then again I guess I haven't worked with a lot of the things that have gone into this so it will just be another learning experience.

Steve

 

[BonzRus]

I got some more house keeping done over the weekend and made a quick silicone mold of just the laser housing as I will need to be able to cast this piece separate from all the rest of the pieces in the block mold for level 1 bios.

Speaking of which, I went ahead and made my first level 1 helmet. It came out pretty good and wieghs in at about 22 ozs. so it is definitely lighter than it's level 2 counterpart. To do this I had to re-insert the silicone plugs that I cut into the upper rear fins for pouring the resin and just used clay to hold them in place.

I even got my oldest son interested in wanting to help mix and spread some resin...

Fresh out of the mold...

Trimmed up and ready to go...

I also made another level 2 helmet and cast another full set of interior pieces. Just trying to build up a bit of inventory.

My leather skiver is on it's way and I should be seeing a few more of the things I ordered to create the next 'rung' very soon so I anticipate another big update towards the weekend.

Bios, bios everywhere...

So close....

Steve

 

[Hippie]

Truly scrumptious
Truly, truly scrumptious.
I want!

 

[wonko]

Spectacular Steve, a true thing of beauty there.  They look flawless in the pics, do they really come out of the mold that clean?  Other than the trimming, is there any other prep work that needs to be done?  Your patience and attention to detail has paid off my friend, they look perfect straight out of the mold!  Thanks for the eye candy...keep it coming!!!

Brian

 

[BonzRus]

Truly scrumptious
Truly, truly scrumptious.
I want!

Thanks Christian....now I have a song stuck in my head and it just won't leave.....argh!    

Spectacular Steve, a true thing of beauty there.  They look flawless in the pics, do they really come out of the mold that clean?  Other than the trimming, is there any other prep work that needs to be done?  Your patience and attention to detail has paid off my friend, they look perfect straight out of the mold!  Thanks for the eye candy...keep it coming!!!

Brian

The level 2 is definitely cleaner coming out of the mold and faster to make than the level 1 but the level 1 is lighter. They both have their advantages and disadvantages. The interior pieces take more time to clean up for the level 2 and the level 1 can't get them so those are the trade-offs. At Jason's and your recommendation I have ordered some Apoxie Sculpt which will help fix some minor bubbles in the pieces coming out of the block molds. I wish I had a pressure chamber for molding the interior detail parts in as I believe I could produce bubble free castings if I did. I wish I actually had a pressure chamber big enough that I could put my whole helmet mold in it as well. The level 2 castings come out clean but there are a couple places where very small air bubbles get trapped and it would be sweet if I didn't have to deal with them at all. They are just a minor annoyance though. Other than that they are relatively clean and ready to paint after the flashing is trimmed away. If anything they might need a thin glaze of some spot putty in places after a light sanding. As I work on the first one I am also preparing what I will need to get some kits put together and ready to go so hopefully I will be up and running when the first one is finished. By up and running I mean they would be available for anyone interested

I forgot to mention in my update earlier that I was also able over the weekend to pin down what I will do to emboss the leather. With the skiver showing up today I will set to work on that this evening and see how far I can get. It would be really good if I could get the leather installed tonight. Then it would just be down to aligning and wiring up the lasers.

Steve

 

[TriLaser]

Haven't commented for a awhile because everyone else has pretty much said everything that needs to be said. Awesome work mate. The process has been great to watch. Now you have got the family helping, you will have a nice mass production line going    haha

 

[Eaglewood]

Steve,
what resin are you using? Just  a thought-- have you tried to vacuum the resin before you pour it to get rid of a lot of the tiny bubbles?-- If you have enough pot life, this may help a little.  Normally you use faster setting resin as we are all so impatient and have to get it out of the mold within seconds!!!

Anyhow-- as usual-- Blessed Hands and thought process.

 

[wonko]

Doesn't seem to be too much work getting them ready for paint Steve.  It's funny you should bring up the vacuum chamber.  My next additions to my shop include one, along with a decent size vacuum table.  I've found some pretty good plans for the chamber, and already have a more than adequate pump, so I'm hoping it won't be too long.  

Brian

 

[XPredX]

Finally catching up to your progress. THAT good sir is complete insanity!!!!!! Unbelievable work. I can't believe how clean everything is. Fantastic piece!

 

[BonzRus]

Haven't commented for a awhile because everyone else has pretty much said everything that needs to be said. Awesome work mate. The process has been great to watch. Now you have got the family helping, you will have a nice mass production line going haha

Thanks Mike! My kids are all eager to help in some way so I just have to channel that energy into something productive. Ahhh, fatherhood. I love it.

Steve,
what resin are you using? Just a thought-- have you tried to vacuum the resin before you pour it to get rid of a lot of the tiny bubbles?-- If you have enough pot life, this may help a little. Normally you use faster setting resin as we are all so impatient and have to get it out of the mold within seconds!!!

Anyhow-- as usual-- Blessed Hands and thought process.

Hey Clay, I am using Smooth Cast 321, about a 10+ minute pot life. Vacuuming could possibly help but I would probably need to go with the 322 if I do. Vacuuming will help get the air out and a pressure chamber compresses the air in the bubbles that may still get introduced with pouring. I can also try pre-mixing the resin parts without shaking them but instead stirring which may help as well. Still experimenting for sure and the casts are very useable as they are but just more time consuming to clean up. Perhaps that is something I can get one of my kids to work on. Thanks for the comments and insights from your experiences They are definitely a benefit to me.

Doesn't seem to be too much work getting them ready for paint Steve. It's funny you should bring up the vacuum chamber. My next additions to my shop include one, along with a decent size vacuum table. I've found some pretty good plans for the chamber, and already have a more than adequate pump, so I'm hoping it won't be too long.

Brian

Hey Brian, no it is not that bad...it is just not 100% either so this is where experience will help as I do more and try different things. I have already improved the block mold castings so much over the first pour which was pathetic. I would love to have the capital to invest in some more tools and equipemant. Ahh well...I have started a list at least. The vacuum chamber sounds interesting...where did you get plans from? I have looked into a rotocasting table and I think I could make my own. They are a tad pricey as well.

Another minor update:

I was glad to get the leather skiver so I set to work on the leather pieces and again it has been a learning experience. The leather I have is probably not what they consider tooling leather and I believe that makes a huge difference in how well the skiver can cut the leather to thin it. I am still able to make it work but with a lot more effort. As a result I was able to get the two largest pieces cut and thinned (Skived) but it took me longer than I anticipated. Here is a shot of it so far.

I still have to emboss these pieces, cut and skiv the two lower pieces and glue them in. Perhaps tonight I will get it all installed.

Steve

 

[BonzRus]

Finally catching up to your progress. THAT good sir is complete insanity!!!!!! Unbelievable work. I can't believe how clean everything is. Fantastic piece!

Thank you very much sir! You snuck in your post as I was replying to the previous posts. Maybe I am a little bit looney but I hope it will be a blessing to others.

Steve