Foam Sculpting My First Bio - Beyond The Final Rung

[BonzRus]

Thanks to everyone for the encouragement. I really appreciate it. As promised here are some more photos of my current progress. It it almost ready for fiberglassing. I got the lower right side cheek and jaw finished and did a little more to round the top of the helmet to the shape I wanted. I have purposefully kept the chin more pointed as it is more the look I am going for. Once I am satisfied with the overall basic shape I will work on trimming a flange on the back/underside to create a lip. I will explain this more as I go.

Then I moved on to sculpting the laser shroud and attaching it.

Then a little spackle and some more sanding...

and it was time to move to the breathing tube port. I will be refining the basic shape in preparation to fiberglass it and refine the detai after it get it fiberglassed. For now I just need the basic shape.

All in all I think it is turning out very well so far..almost there.

I looks quite ominous propped up on my workbench. I hope you like it so far...

 

[Kithunter]

amazing proces. thank for sharing it with the group...

just goes to prove you can make a kick ass piece without dropping tons of money on it

 

[BonzRus]

amazing proces. thank for sharing it with the group...

just goes to prove you can make a kick ass piece without dropping tons of money on it

Thank you very much...I have found the ingenuity and creativity of the folks here on the Lair to be amazing to say the least. It is really cool to see the many ways members are using that ingenuity to create their various preds. So many good ideas...that is one of the things I like about this place.

 

[BonzRus]

Just a quick update...I decided I just wasn't happy with where I had positioned the laser shroud so I decided to remove it and reposition it higher on the eye brow and set it a little deeper as well...something I just couldn't do with the location I had it in without creating a problem with the back corner of the eye. Here is a quick photo showing the part removed and the beginnings of relocating it. I will post before and after photos once I am finished. This will be good to show how easy it is to make a substantial change.

 

[hannay07]

That is just so cool making that out of foam. You did an exellent job.

 

[REYALS1]

This is really a great walk through.

Thanks for sharing.

 

[Canalien]

This was very well done Thank You for sharring your work look forward in seeing more!
cheers
Rhonda

 

[BonzRus]

Again, thank you for all the encouragement. What I am doing here is not much compared to the preds I have seen on the Lair and I continue to be inspired by what I see coming from the members here. They are a creative bunch to say the least. I have reworked the lasrer shroud setting it higher on the brow and inward towards the centerline. I also took some material off the outside of it to reduce its size a bit. It is now more to my liking and less prominent. Here are a couple before and after pictures. I am now working to thin out the brim and create a lip or flange all the way around the underside to prepare for fiberglassing.

Before

After

Here are a couple additional shots from a different angle showing how the rear brim looks. I will be thining the underside of these next and will post better photos as I do.

I am starting to feel the need to give him a name...any suggestions?

 

[Uhlakk]

Holy moly.... what cool work!

It's awesome!


Name? What about P1 light (weight)

 

[made007]

They sell that foam online? I might need some for my dbz cosplay, ive never seen that kind of foam

 

[BonzRus]

Holy moly.... what cool work!

It's awesome!

Name? What about P1 light (weight)

Thanks Uklakk! It definitely is light weight at this time.

They sell that foam online? I might need some for my dbz cosplay, ive never seen that kind of foam

Made007 greetings, you can get it at your typical home improvement stores like Lowes or Home Depot and I am sure there are others. I do not know about ordering it online but I would think you could if you can't find a local source. It is just your standard foam insulation board. Comes in 4' x 8' sheets and thicknesses of 1/2", 3/4", 1" and evn 2". Sometimes it is pink but the sheet I got is a light green..I actually found a piece of 2" thick foam about 2' x 3' beside the interstate last night that I stopped and picked up. Must have blown out of the back of someones truck on the way to the dump...it had only minor damage but to me it was like finding a gold nugget!

 

[BonzRus]

I began working on the underside of the helmet to create a flange/lip around the edge. I am still not sure just how far I will take this as the more foam I remove the more delicate it becomes. I would like to get to the back side of the eyes to create a flange for mounting the lens before I fiberglass it. At this point I am looking for alternative ways to remove the foam besides my knife but I always enjoy a challenge. Once I have the outside of it fiberglassed I can use a Dremel to trim the underside fiberglass edge and prepare to finish the inside. At that point I will have several options for how to do that. I would like to have the inside of the helmet finished as well similar to this.

Just my preference. I can add the detail prior to casting. I am still trying to think three steps ahead as I go and as a result sometimes I trip myseld up. My plan is to eventually make a two part mold for casting it though.

This is all I have for the moment. I will probably order my expoxy resin and micro-balloons next week and I am still undecided on the weight of fiberglass cloth I will use for this. Not a big deal though.

 

[BonzRus]

I decided to try my cordless Dremel with a large sanding drum on low speed and it worked great! I was concerned it would get too hot and melt the foam but as long as you keep it moving it is not a problem. As a result, hollerin' (as they would say here in the South) this thing out will not be as much of a problem as I originally thought. I was able to break through to the middle back-side of the eyes in just a few minutes and while it does make more of a mess it just brushes or blows right off. Maybe I will end up fiberglassing the underside as well. Sorry about the blurry picture.

 

[REYALS1]

Simply amazing work. You certainly have this down to an art, it seems.

 

[BonzRus]

Simply amazing work. You certainly have this down to an art, it seems.

Thanks again REYALS. I do enjoy working with this material. It opens a door to a lot of possibilities for me...things I probably couldn't otherwise do. i am getting anxious to get to the next phase of construction though...hopefully next week.

 

[hez1]

Very cool...it would simply never have occurred to me to work in this material, but it's come out great!

 

[made007]

Thanks Uklakk! It definitely is light weight at this time.



Made007 greetings, you can get it at your typical home improvement stores like Lowes or Home Depot and I am sure there are others. I do not know about ordering it online but I would think you could if you can't find a local source. It is just your standard foam insulation board. Comes in 4' x 8' sheets and thicknesses of 1/2", 3/4", 1" and evn 2". Sometimes it is pink but the sheet I got is a light green..I actually found a piece of 2" thick foam about 2' x 3' beside the interstate last night that I stopped and picked up. Must have blown out of the back of someones truck on the way to the dump...it had only minor damage but to me it was like finding a gold nugget!

I have a home depot nearby, do you know in wich dept they have it?

 

[BonzRus]

Very cool...it would simply never have occurred to me to work in this material, but it's come out great!

Thanks Hez! I certainly enjoy working with it as you can tell. I have also enjoyed seeing some of your threads on the Lair. Very good stuff...

I have a home depot nearby, do you know in wich dept they have it?

Made007, typically it is in Building Materials...usually with the other types of insulation (Pink Owens Corning Fiberglass in rolls). The Lowes near my house has it standing upright on a shelf near panneling and moulding stuff. I have become somewhat of a foam-smith also making LARPing swords and shields out of closed cell foam, PVC and duct tape...my kids love 'em. I have really enjoyed watching your Terminator Bio come along. I hope your next attempt to make a mold goes better than your first.

 

[made007]

Thanks, i hope so too, i took the next week off, so we'll see, thanks for the info

 

[MrBarlow]

Beautifully done. How long have you been working on it so far?

Looking forward to more updates!