Helmet molding advice needed! Darktrooper helmet!

[tubachris85x]

I've decided to push through and get this sucker done. I desperatly need to make a transition mold, but I really don't want to spend $$ for silicone that I'm literally going to only need for one casting.

So, my alternative is to make a plaster mold and a plaster cast (or resin?). The thing though, is that this is going to be a massive mold. I have planned it as such that I'll have to break it up into 2 sections, maybe 3 or even 4. I just need input!

To give you an idea of scale, the helmet eats an MR clonetrooper bucket like nothing!

So here are the options for the mold break up that I was thinking about. Any input would be greatly appreiciated!

-TC

 

[tubachris85x]

Hmm this is surprising :/

 

[KaanE]

I would do three pieces. Faceplate, dome and back. Just like an old FX bucket.

 

[tubachris85x]

I would do three pieces. Faceplate, dome and back. Just like an old FX bucket.

Are you implying that set up for vacum forming?

 

[dreaminspired]

chris, you need to finish this damn helmet, man!!!
i have no advice on mold making, but maybe you can try to pick evo3's brain or sgb or something?
i'd love to see either you or rick finally get one of these into production for the fans out there.

 

[tubachris85x]

chris, you need to finish this damn helmet, man!!!
i have no advice on mold making, but maybe you can try to pick evo3's brain or sgb or something?
i'd love to see either you or rick finally get one of these into production for the fans out there.

I'm trying! GAR! Just need $$ and no more car repairs draining my account!

That's why I'm trying to go the plaster mold route for now, so I can get started on making the final master!

 

[KaanE]

It's a vacumm setup but it's also a nice mold setup

 

[tubachris85x]

It's a vacumm setup but it's also a nice mold setup

Hmm, kinda interesting. I'll think it through, I am just afraid of having one big mass mold parts since this will be plaster

My next issue is having to close the hole on the bottom of my sculpt

 

[EricHart]

If I'm looking at this correctly, option 2 has undercuts that won't work in plaster. Option 1 might be do-able as long as those sides aren't too close to being parallel.

 

[tubachris85x]

Thanks for he input. Getting kinda spooky for me cause if I do the mold wrong in plaster, I can ruin the sculpt. Just got paid, so I can go get the materials needed. I'm not sure how many bags I'm going to need. I'll have to build the mold box first and then do the math...

Otherwise, i'm thinking of either 1 or 3. 3 moreso because I should be able to handle the mold halves with more control.

 

[tubachris85x]

Crap. Just thinking about this. I might just be better off doing it in silicone...IDK anymore!

 

[KaanE]

Or you could scale the helmet around a 7% and do the mould with latex. It's cheaper but shrinks around 7-10%

 

[tubachris85x]

Or you could scale the helmet around a 7% and do the mould with latex. It's cheaper but shrinks around 7-10%

Is that a significant difference? It's hard to really see that as I'm horrible when it comes to mathematics.

I pride myself with the size as I know it will be theargest trooper helmet out there when done!

 

[tubachris85x]

Here are some actual pictures for a better understanding. There aren't really any undercuts!

 

[Jessica]

That is a cool looking sculpt!

 

[clonesix]

Do you just want one copy? Then make a plaster (stone) 2-piece mold, release it really well, and laminate fibglass into it. Then smash the plaster and pull out the piece.

 

[tubachris85x]

Do you just want one copy? Then make a plaster (stone) 2-piece mold, release it really well, and laminate fibglass into it. Then smash the plaster and pull out the piece.

Fair enough! My only thing is that I'm not very proficient in fiberglassing. I've tried multiple times at casting with it, but I don't think I'm using the right fiberglassing resins, at least.

My alternative would just to make one solid resin casting, but thats going to be expensive as hell

 

[KaanE]

Is that a significant difference? It's hard to really see that as I'm horrible when it comes to mathematics.

I pride myself with the size as I know it will be theargest trooper helmet out there when done!

It's all about the size of the object moulded. If it's a 1mm piece, it'll become 0.9mm, not diference for us (yes for the SS builders). But if the things measures 1km (1000 meters) the casted piece would be 100 meters shorter, and there is diference.

 

[tubachris85x]

It's all about the size of the object moulded. If it's a 1mm piece, it'll become 0.9mm, not diference for us (yes for the SS builders). But if the things measures 1km (1000 meters) the casted piece would be 100 meters shorter, and there is diference.

True. I would just like to try and retain it's true size :/

I was just looking through some Freeman brand supplies. IDK, hell, I just might go with a solid resin casting from a two part plaster mold as clonesix suggested.

If the resin is going to cost less then materials for rebound 25 silicone, then yea. I can already tell that a solid resin buck will be much more durable for what I need to do to finish it off.

 

[tubachris85x]

Actually, Shell Shock is a brushable plastic resin. That can work!