JFcustom's FOAM files

Discussion in 'Replica Costumes' started by JFcustom, May 24, 2012.

  1. JFcustom

    JFcustom Sr Member

    Trophy Points:
    1,085
    Hi,

    After a basic but effective five-days-built Iron Man Mark IV, I wanted to improve and share my speed-building technics to allow everyone having kids and a full-time job to be still able to build a full foam suit in far less than a month. And it begins with releasing some suitable *.pdo files.
    By suitable I don't mean at all that the other guys who unfold for foam should better drop their work right through the gogs. Not at all. By suitable I mean that the templates below can only be used under certain restriction of material :

    at first you must use some foam mats, or foam roll, or whatever else, much larger than a common paper sheet. Then, you may use some cheap foam, because these templates generate a impressive amount of waste. And at last, the more your foam is flexible, the more easy will be your build. This point depends mainly of the thickness of this foam. I would recommend somewhere between 5 and 10mm. I use 7mm.

    The way I unfold allows each curve and bulge-shaped effect to be obtained without the need of a heat gun. It has occurred that these templates work fairly well with corrugated cardboard, and also, through proper tweaking, for aluminium panels.
    But if you plan to use some sheets of foam of one square foot, or one inch thick, or almost unbendable, you won't be able to use these templates. About flexibility, here's a quick illustration of what you'll often have to do with your foam (yea I know, it's paper on the photos, but it's only an illustration) :

    coldcurve01_th.jpg coldcurve02_th.jpg coldcurve03_th.jpg coldcurve04_th.jpg coldcurve05_th.jpg

    This thread aims to gather the models I've unfolded with both "foam" and "speed-build" in mind, as well as the tips that come along with the files. You may notice that some esthetical details are often missing, details like grids, holes, screws, notches, indentations... They have been removed from the templates to build faster, and are called to be added on your own once the armor part is built. Every missing detail can always be implemented afterward. The final shape remains unchanged, you won’t have any ‘more angular’ nor ‘more inflated-like’ body parts than with other files.

    At the end we obtain some pepakura files with less and larger pieces, foam flaps for stronger and discrete overlap gluing, and in one word a better compatibility with foam shapeability.

    Well at least I assume it is...

    __________________________________________________

    The files below are, and will remain, unlocked and shared freely for all to download and use, since they are used in the evident respect of legality. Do not go thinking so far that I'm plenty of buckets full of free time to work on these files, because it's not the truth at all. And in order to prevent my wife from strangling me, I promised to add this link.

    __________________________________________________

    For Iron Man mark 4 and 6 I robbed Robo3687's files, I stole the mark VII in DarkSide501st's pockets, and Dancin_fool has modeled the mark III. A big thank to you, without your work all of us would still keep saving the world in underpants.

    If it happens you find here a(n other) file that is not fully credited, please contact me.

    All male suits are default scaled for a 6' guy.

    Here we are :

    P1010473_th.jpg mkvi.jpg rar.gif
    robo3687's Iron Man Mark 4/6 - unfold for foam by JFcustom.rar


    I've colorized here where to connect the parts together :
    torso-connect-01.gif

    And here, how I connected collar plates to the top of the back/chest :

    clip6.jpg clip5.jpg

    anyway, it's the way I did... The result is a one-piece torso that you put on just like a T-shirt.

    Iron%20Man%20mark7%20by%20Karol%20Siemieniago_th.jpg rar.gif
    Iron Man mark7 by Karol Siemieniago - minor edit and foam unfold JFcustom.rar

    Incredibly both movie-looking and simple to build.

    8.2_th.jpg rar.gif
    DarkSide501st's Iron Man Mark VII - v1.0 - unfold for foam by JFcustom.

    I have to reedit some files from the beginning for this suit to be doubt-proof and fully workable. I'll should have join a readme file for this one, because I think that some tips need to be explain before you drive straight against the wall...
    Note that gloves, brace, collar, collar plate, and neck are missing from MkVII package. You can pick them from Mk2, 3 or 4.

    IMextremisv1.jpg rar.gif
    EyeofSauron's Iron Man Extremis - unfold for foam by JFcustom.rar


    IMextremisv2.jpg rar.gif
    Iron Man Extremis v2 - foam unfold JFcustom.rar


    classicIM.jpg rar.gif
    classic iron man provided by EyeOfSauron - foam unfold JFcustom.rar


    Ultimate_Iron_Man_th.jpg
    Marvel, Zabanna, and BenStreeper's Iron Man Ultimate V2
    - unfold for foam by JFcustom.

    Link to the rar file in the post by CSM-101 (me) time stamped 02-18-2013, 02:25 AM

    h-tribes-s.jpg rar.gif
    Tribes Ascend - heavy armor - JFcustom foam files.rar


    WarMachine_th.jpg rar.gif
    Robo3687's War Machine - unfold for foam by JFcustom.

    All included but heavy weapons. Helmet design by Stark1138.

    patriot.jpg rar.gif
    Iron Patriot by Jackieisrockin - foam unfold JFcustom.rar


    briareos250px.jpg rar.gif
    Briareos by C2/Lord Harnor/Dung0Beetle/JFcustom - foam unfold JFcustom.rar


    guyverfoam_th.jpg rar.gif
    Guyver the Bioboosted Armor - FOAM edit and unfold JFcustom.rar

    At last. Full from head to toes. The 6 tubes on the sides of the chest, as well as the spheres on the helmet are left to be freehanded.

    predator.jpg rar.gif
    Predator - foam edit & unfold JFcustom.rar


    cybermanv1.jpg rar.gif
    Cyberman - foam unfold JFcustom.rar


    c3po.jpg rar.gif
    c3po.rar


    rexphaseII.jpg rar.gif
    BSD's Rex PhaseII - foam ufold JFcustom.rar


    IM_mk2.jpg markiii.jpg rar.gif
    Dancin_Fool's Iron Man MkII/MkIII - unfold for foam by JFcustom.

    To go at simplest, every detail missing from the original model (grids, holes, screws, notches, indentations...) will have to be added manualy afterward by directly sculpting them into the foam. Please refer to Dancin_Fool's files or included ref pics.

    vanquish_armor.gif rar.gif
    Vanquish ARS provided by Tumbucu1 - unfold for foam by JFcustom.

    A huge painting work to make this one look good, but I think it can worth the time spent. The files in the rar may be updated without warning during the coming days.

    thor.jpg rar.gif
    Thor - unfold for foam by JFcustom.

    Helmet model by Dung0beetle, I don't know who created the other parts...

    pepper%20potts%20rescue%20armor.jpg rar.gif
    Pepper Potts Rescue Armor - foam edit JFcustom.rar

    Credits :
    Back and torso modeled by Eirth @405th
    Arms from a Halo mkVI modeled by Robogenesis @405th
    Helmet is IM comic version from EyeOfSauron
    All other parts provided by EyeOfSauron's Extremis suit.
    All of these post-edited to fit a woman's body.

    An overview pic here.
    The suit is scaled for a 1m70 heigh girl. (ie 5'7")


    nightingale.jpg
    Nightingale female suit - The Elder Scrolls V - Skyrim - foam unfold JFcustom.rar



    dfw.jpg dfw2.jpg dfw3.jpg rar.gif
    Skyrim - Female Daedric armor - foam unfold.rar



    snowwhite.jpg rar.gif
    Snow White Armor - model and foam unfold JFcustom.rar



    mk1.jpg rar.gif
    Iron Man MK1 - cave suit.rar


    spacemarine.jpg rar.gif spacemarine - foam unfold JFcustom.rar

    laputafull.jpg rar.gif Laputa's Soldier - 7ft tall display - foam unfold JFcustom.rar


    scryed.jpg
    S-CRY-ed Kasuma's arm - foam unfold JFcustom.pdo



    predator%20biohelmet%20-%20foam%20unfold%20JFcustom.jpg
    Rhinoc's predator biohelmet - foam unfold JFcustom.pdo



    Darkside501st%27s%20iron%20patriot%20helmet%20-%20foam%20unfold%20JFcustom.jpg
    Darkside501st's iron patriot helmet - foam unfold JFcustom.pdo



    tdkcowl%20-%20foam%20unfold%20JFcustom.jpg
    TDK cowl - foam unfold JFcustom.pdo


    arkham.jpg
    Batman Arkham cowl - foam unfold JFcustom.pdo


    Batman-AO.jpg
    Arkham Origins Batman cowl - foam unfold JFcustom.pdo


    DCU-hawkman.jpg
    DCU - Hawkman cowl - foam unfold JFcustom.pdo


    DCU-fate.jpg
    DCU - Fate helmet - foam unfold JFcustom.pdo


    DCU-hawkgirl.jpg
    DCU - Hawkgirl cowl - foam unfold JFcustom.pdo


    Arkham-Deathstroke.jpg
    JFcustom's Arkham-Deathstroke.pdo



    deathstroke.jpg
    Injustice - Deathstroke Helmet - JFC foam.pdo



    starlord.jpg
    Guardians of the Galaxy - StarLord helmet.pdo - model and foam unfold JFcustom.pdo



    titanfall01.jpg
    Titanfall pilot helmet 1 - JFC foam.pdo



    freedom%20gundam%20helmet.jpg
    freedom gundam helmet - foam unfold JFcustom.pdo



    landmate%20helmet.jpg
    Landmate helmet - foam unfold JFcustom.pdo



    classic%20iron%20man%20helmet%20by%20EyeofSauron%20-%20foam%20unfold%20JFcustom.jpg
    classic iron man helmet by EyeofSauron - foam unfold JFcustom.pdo



    omarbou1mkvii.jpg
    omarbou1-ironmanmark7v2helmet-jfcfoam.pdo



    Iron%20Patriot%20by%20Jackieisrockin%20-%2013%20-%20helmet%20-%20foam%20unfold%20JFcustom.jpg
    Iron Patriot by Jackieisrockin - 13 - helmet - foam unfold JFcustom.pdo



    Multi-hero%20cowl%20-%20Blue%20Beetle%20pattern%20-%20model%20and%20foam%20unfold%20JFcustom.jpg
    Multi-hero cowl - Blue Beetle pattern - model and foam unfold JFcustom.pdo


    wolverine.jpg
    Wolverine cowl - foam unfold JFcustom



    rinzler.jpg
    Rinzler helmet - foam unfold JFcustom.pdo


    obito.jpg
    Obito war mask.pdo


    Embo%20hat-shield.jpg
    Embo hat-shield.pdo

    About the thickness, you'll just have to add two or three circles of foam between the two layers to make it keep its shape, just like that :
    embo-frame.jpg

    c3po-head.jpg
    c3po-head.pdo


    darkvader.jpg
    Dark Vader helmet - foam unfold JFcustom.pdo



    Dredd%202012%20helmet.jpg
    Dredd 2012 helmet by Dung0Beetle and Blaxmyth - Foam edit and unfold JFcustom.pdo



    dwarf%20helmet.jpg
    Dwarf helmet.pdo



    jangofett.jpg rar.gif
    Jango FETT helmet - foam unfold JFcustom.rar



    Rocketeer.jpg
    Rocketeer helmet - edit and foam unfold JFcustom.pdo



    DrFate.jpg
    Dr.Fate helmet - foam unfold JFcustom.pdo


    Guyver%203%20helmet.jpg
    Guyver 3 helmet - foam unfold JFcustom.pdo



    yoda.jpg rar.gif
    Yoda's head.rar



    Dung0beetle%27s%20Spaceballs%20Dark%20Helmet%20-%20foam%20unfold%20JFcustom.jpg
    Dung0beetle's Spaceballs Dark Helmet - foam unfold JFcustom.pdo


    and the little prop that comes along :


    coffeecup.jpg
    Spaceballs - Dark Helmet's coffee cup.rar



    mrf.jpg
    BTTF Mr. Fusion - JFC foam.pdo

    Mind the scale before printing.


    Daft%20Punk%20-%20Cama900%27s%20GuyMan%20Helmet.jpg
    Daft Punk - Cama900's GuyMan Helmet - Foam edit and unfold JFcustom.pdo



    Daft%20Punk%20-%20Dung0Beetle%27s%20Thomas%20Helmet.jpg
    Daft Punk - Dung0Beetle's Thomas Helmet - Foam edit and unfold JFcustom.pdo



    sg%20-%20shoulder%20cowl%20base.jpg
    sg - shoulder cowl base.pdo



    sg%20-%20woof.jpg
    sg - woof.pdo



    sg%20-%20chirp.jpg
    sg - chirp.pdo


    pumpkin.png
    foam-pumpkin.pdo


    christmastree.jpg
    christmastree - foam unfold JFcustom.pdo


    Few accessories that come along with the Predator suit :

    weapons :

    predatorbattledisc.jpg
    predator-battledisc.pdo


    predatorspear.jpg
    spear.pdo


    and trophys :

    vertebra.jpg
    human vertebra.pdo

    Build several ones with a slightly changing scale to get a realistic full spine.

    skull.jpg
    (almost) human skull.pdo


    alienheadpdo.jpg
    alienhead.jpg
    Alien head - provided by Movieman - foam unfold JFcustom



    And to both solve the issue of the lower eyes that happen to bulge way out, as described here, and improve the details of the ears area, here's an enhanced unfolding version of Sharkhead's Iron Man Helmet :

    faceplatepdo.jpg faceplate07_th.jpg earsarea_th.jpg
    Sharkhead7854-ironman-helmet-foam-unfold-by-JFcustom.pdo

    Labsic%27s%20Mk8%20helmet%20-%20foam%20unfold%20JFcustom.jpg DSC_0928_th.jpg DSC_0930_th.jpg
    Also Labsic's Mk8 helmet - foam unfold JFcustom.pdo


    Loki-Helmet.jpg
    Loki Helmet by KaiserLee - foam unfold JFcustom.pdo


    Tip : at the horn gluing stage we have three loooong pieces to snap together. To be sure to obtain a well curved horn, you may want to face them up first and glue them point by point, this way :

    lokihorntip.gif

    This process should be applied to glue correctly any long side in general.

    You may also applie these process if needed : thin the foam on the gluing area, or plainly cut up your pieces of foam without caring about the dot-lined overlap you'll see on the pep files. Illustration :

    6vs12mm.gif

    The dotted lines along the borders of the paper templates are here to delimitate
    - the real outter side of the suit (in grey)
    from
    - the strip that will recieve glue and will be overlapped (in blue) by another piece of foam.

    If you're using your 12mm foam, by thinning the blue area you can act like if you were working with some 6mm foam, or you can also completely remove this blue edge depending of the method you plan to assemble your foam pieces.

    I've been asked if I had used some 2, 3 or 5 mm when building Sharkhead's helmet, in fact it was some 7mm foam. The illusion was due to the fact that I used several ways to snap the pieces of foam together, depending of the rendering I expected at the surface. Low, medium, heigh, and progressive step :
    indentations.gif
    Gluing pieces side to side will probably be less strong, but will it be not strong enough ? I can't say. No dammage here so far.
    One simple thing also is you don't have to mix the dotted lines that represent a mountain or a valley, with the dotted lines that delimit a gluing area. But it might not be much harder on the templates than on the picture below :
    unfoldedcubewtabs.gif
    In case of doubt, always refer to the 3D view of Pepakura viewer... :)

    I've also been asked to show the way I translate the dotlines from the paper patterns to the inner side of the foam pieces.

    We assume a suit is always symetric, we have only one paper template (let's say it's the right side one) and we are at the point we've already managed to cut up two mirrored foam pieces from it.
    tr2foam07_th.jpg

    So, here I lay down the right paper template over the inner side of the left foam piece. With a pen I punch a hole at every strategical point, in order to locate the placement of the lines.
    tr2foam01_th.jpg

    When removing the paper, I see the dots my pen made.
    tr2foam02_th.jpg

    From them I can draw the same lines onto my foam.
    tr2foam03_th.jpg

    Now, I flip my paper mask and lay it over the other foam part, the right side one.
    The printed side of the paper is hidden, I can't see my dot lines anymore but I don't care : I still have my previous dot holes. I use my pen once more to mark the placement of these holes.
    tr2foam04_th.jpg

    Here I am. Now I can bin my paper pattern...
    tr2foam05_th.jpg

    ...and trace the lines on this second and last foam piece.
    tr2foam06_th.jpg

    My printed lines are accurately transposed, I can cut my hills and valleys...
    tr2foam08_th.jpg

    To fill the remaining gaps, and unexpected valleys, and overall every 'factory-dammages', I don't think any sandable product can go well. Because foam is flexible, and something you can sand is not. As a result your join will keep on breaking at every bending. I've successfully tryed a simple and common alternative : the silicone bathroom mastic-glue-gun.
    silicone-sealant-in-a-caulk-gun.jpg
    It sticks, it fills, it's slick and smooth, and it can be shaped. The only thing is you must paint it or primer it with any spray you want before it's dry, or nothing will further hold on to this stuff.

    _______

    If it's your first step into foam, I suggest you to try your hand on this realy quick and and quite simple Cap' helmet :

    cap01_th.jpg

    Howto :

    printalignmentmarks.gif

    After having ticked "print alignment marks for multiple pages" in "setting / print setting", you can print your pages. Then, cut away the top and left margins of each of them, and then tape all of them together to obtain a laaarge single page.

    Then, cut out your paper pieces just like they are.

    If these pieces are too large for your foam hight or width, you'll have to choose between cutting your piece of paper in smaller parts to match your foam sheets size, of seaming multiple foam sheets to obtain a single and large enough foam sheet to match your paper piece size.

    Step by step :
    Be sure to set A4 or Letter properly, or you'll run the risk to print outside the paper.
    You should tape the sheets before cutting the patterns :

    1. print your sheets
    2. tape your sheets
    2.1- match the alignment marks

    pdotape01.jpg

    2.2- tape the corners

    pdotape02.jpg

    2.3- tape the whole meeting sides

    pdotape03.jpg

    ... and only then you can cut up your masks. This way you can instantly notice if something's wrong before cuting and before taping, and It prevents both hazardous taping and multiple pieces parts spreading.

    3. cut your paper masks
    4. cut your foam from the masks
    (OR gather 3 and 4 by laying your paper upon your foam to cut both at the same time if you can, you'll save time)
    5. you get less and bigger foam parts, you save gluing time, and less junctions means nicer curves an inproved "anti-aliasing".

    Now, tips.

    Classical cardboard peping is fantastic. Cut all of the pieces, glue them as shown on pepviewer, and from Gabon to Peru you'll get exactly the same shaped armor part.
    Foam peping doesn't goes exactly the same, since you use an elastic and springy matérial you can actualy not fold so easily.
    However it can be bent and stretched as you like, and it has a practical thickness !

    Sharp cutting and clean gluing will make the difference between Iron Man and Jabba the Hutt. So here are some simple tips I used (glue is blue) :

    Cut all your foam parts first with no particular angle, some quite right angles would go well, and then, only while assembling, you can adjust inclination edge after edge.

    The idea :
    anglecut.gif

    The practice :
    gluing4.gif

    The result (don't ask, yes it's another piece) :

    DSC_0824_th.jpg

    It's simple as possible : each time the surface of the armor makes an angular outward inflection (not a simple curve, but an real palpable angle), you must make the angled cuts.

    Vcut00.jpg

    Vcut01.gif

    Shaping mountains and valleys :

    You'll often have to give a shape to a single piece of foam in order to decrease the amount of seams. This will help a lot :
    readme1_th.jpg

    I've been asked many times for a detailed howto, so here are the steps to follow :
    To make a valley, the only trick is not to cut your foam from side to side. Your blade should never cross the outer side of the foam piece.

    1- draw your valley with any pen on the inner side of your foam piece,
    2- cut along this line by an angle of 90° in a single pass, without perforate the foam,
    3- fold your valley to its desired angle,
    4- apply glue inside the notch,
    5- wait...
    6- release, it's done.

    Making a mountain is nearly the same, but you have to make a double cut, in order to remove a long toblerone-shaped piece of foam.

    1- draw your mountain on the inner side,
    2- cut on either side of this line by an angle of 45°, more or less depending of the desired salient of your mountain, each cut in a single pass, without perforate the foam,
    3- remove the toblerone, and apply glue inside the notch,
    4- fold your mountain to its desired angle,
    5- wait...
    6- release, it's done.

    gluing3_th.jpg

    If you flunk, don't panic : re-heat the cold glue so you can inflect the angle.
    The most important thing is to keep your blade *-sharped !

    And before you ruin your WM, I suggest you could pactice with waste foam pieces... until you're self-confident.

    forcing a curve :

    readme2_th.jpg

    And here are some close'ups of the way I use the overlaps to build quite cleanly most of a suit's parts. Here, a back part.

    DSC_0820_th.jpg DSC_0828_th.jpg DSC_0829_th.jpg DSC_0831_th.jpg DSC_0833_th.jpg DSC_0834_th.jpg

    No this picture hasn't been photoshopized, and yes I use a common glue gun :

    DSC_0856_th.jpg

    strengthening rotating joins (glue is used as standalone) :

    readme4_th.jpg

    Many of you asked me the way I get net junctions and how I could glue pieces together without any glue overflow. In fact, there IS always glue overflow... but not outside the suit.

    bad -> readme5b_th.jpg

    good -> readme6b_th.jpg

    Easy.

    A quick example of the cheapest pivoting juncture ever :

    from a plastic bottle
    coke01_th.jpg

    spare all parts
    coke02_th.jpg

    cut the bottleneck this way
    coke03_th.jpg

    glue the ring inside the border of a round hole in the upper foam piece

    coke04_th.jpg

    glue the bottleneck trough a second hole in the lower foam piece
    coke05_th.jpg

    and reassemble the same it primarily was.
    coke06_th.jpg

    Screw the plug back, you're done.
    coke07_th.jpg coke08_th.jpg

    Depending on the thickness of the foam, once screwed it may jam.
    In this case the trick is to cut out few millimeters from the bottom of the cap :
    cokecap.jpg

    That will release the tightening.
    And if the plug stands out too much for the smooth design you expected, cut out a ring from the top of the neck too.

    my cheapest operational ARK reactor for moneyless

    - you need -

    An Evian bottle bottom, 2 inchs height :

    evian1_th.jpg evian2_th.jpg

    One of this kind of pics, of your choice, printed on the thiner paper you can find, cut along the dotted, and then oiled for a better transparency :
    iron_m1_th.jpg

    iron_m10_th.jpg iron_m11_th.jpg iron_m12_th.jpg iron_m13_th.jpg

    iron_m14_th.jpg iron_m15_th.jpg iron_m16_th.jpg iron_m17_th.jpg

    A 80mm white round reflector, as you can find at the front of caravans or trailers (keep only the transparent part, of course, but better is to specify it however) :
    reflector_th.jpg

    A led(s) push-spot
    led1_th.jpg led2_th.jpg led3_th.jpg

    and a roll of tape
    scotch_th.jpg

    - HOW TO -

    Fill your bottle's bottom with
    1. pic of the ARK, printed side turned down,
    2. reflector, rugged side down, slicky side up in front of the leds,
    3. led spot, lights turned to the reflector
    4. cross tape your bottom's bottle to keep all inside in place.
    5. Insert the thing in your chest, it fits perfectly, and holds alone.
    2bucksARK.jpg

    Push, it works.
    Price : 2$

    In a similar spirit, have a look at Freaklord's Cheap Iron Man Repusors, that are well worth to be referenced and earn to be quoted.

    Joining articulated (and also some sealed) parts :
    I used to work as graphist in a publicity agency, and we had always somewhere in the office a couple of useless and sun-faded color charts.

    chart0_th.jpg

    And ?
    And I kept thinking that the potential of these pretty little plastic juncture clips were heavyly underexploited.

    chart1_th.jpg

    So I ordered a pack of 100 pieces, as it almost doesn't costs anything.

    clip1_th.jpg clip2_th.jpg clip3_th.jpg clip4_th.jpg

    You can find some here or here or here or here... of various shape, color, diameter and thickness.

    clip5_th.jpg clip6_th.jpg clip7_th.jpg clip8_th.jpg

    And I promise you some discret and incredibly easy attaching for mobile parts (knees elbow toes...) as well as sealed parts such top chest, flaps, handplates, spin and so on... depending of the pressure when cliping.

    Those discrete flat-headed rivets on my kneese are very handy and efficient. But they can not be unfasten (except by using barbarian way). Once cliped, you only have to chose between : you leave it alone, or you clip it harder. The axis is toothed so they act just like you car's hand brake.
    Coke caps are easyer to find, and can be unscrewed. And to quote Jonny, "the botte neck is quite wide so it's less likely to rip the foam".

    Might be a good alternative to the clips I use (and maybe available in the US ?)

    _______


    How to sharpen a blade.


    You're allowed to disbelieve : I use the same blade since april. I'm a tightwad... :lol

    If foam by itself is able to blunt a blade, then something as soft as foam may also sharpen it. The main trick is NOT to take an aggressive nor fierce material. No whetstone, no grindstone, no polishing Dremel tip, not event the thinest sanding paper... Something just like Death, in "Reaper man" from Terry Pratchett, is sharpening his scytheblade using wind and moonlight until it can even cut a conversation.

    Sharpener multipurpose SANSON cristal - Precise and fine sharpening
    s_51.jpg

    A single and light pass, your blade slides between two tungsten slabs, it takes half a second, and then it cuts better than when it was new.
    It's not a joke.
    It really cuts better than when it was new.
    5 years guarantied.
    It makes my life a thousand times easier. I don't know how I could do without for so long...

    _________________________________

    ArmorAsylum video(s) :

    Well it's me, in fact... on ArmorAsylum channel



    Cullen Cosplay video(s) :

    He's one of us. If you don't recognize his face, you'll recognize his work ^^
    Aside the flowers he sends me, he shows and explains for real how to use foam along with the templates available on this thread. Trust it's much more efficient than reading 50 pages. Keep tunned on Cullen Cosplay channel...

     
    Last edited by a moderator: Nov 8, 2018
  2. Indigogyre

    Indigogyre Well-Known Member

    Trophy Points:
    566
    Re: Speed-building files : FOAM Iron Man MkVII within 4 days...

    Thanks.

    [​IMG]

    No, I will not race you. The pieces are not in the right positions, I just threw them down quickly to take the photo.

    Dean
     
  3. ArtDeco

    ArtDeco New Member

    Trophy Points:
    17
    Re: Speed-building files : FOAM Iron Man MkVII within 4 days...

    Thanks for sharing! Subscribed to see this happen! :)
     
  4. teenwolf87

    teenwolf87 Member

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    Re: Speed-building files : FOAM Iron Man MkVII within 4 days...

    ahah ur the man!
     
  5. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files : FOAM Iron Man MkVII within 4 days...

    EDIT : content moved to first post
     
    Last edited: Aug 22, 2012
  6. Shades

    Shades Well-Known Member

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    Re: Speed-building files : FOAM Iron Man MkVII within 4 days...

    Lots of protips here. Nice work.
     
  7. endo500

    endo500 Active Member

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    Re: Speed-building files : FOAM Iron Man MkVII within 4 days...

    Great tips. The visualizations really helped make things clear. It really helped clarify things that some people have been trying to say.
     
  8. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files : FOAM Iron Man MkVII within 4 days...

    EDIT : content moved to first post
     
    Last edited: Aug 22, 2012
  9. sjorsjo91

    sjorsjo91 Well-Known Member RPF PREMIUM MEMBER

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII

    Subscribed. Love this. I use cardboard for my MK VII build and i think this will be very helpfull.
     
  10. Nobody

    Nobody Well-Known Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Thanks for all of the tips and the files but the link to your MK VII files is broken
     
  11. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Yes I know...

    Sorry, my enhanced files will be back if I get the original creators agreement.
     
    Last edited: May 25, 2012
  12. LadyLoo

    LadyLoo New Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Oh man those illustrations are great, adding them to my growing compendium of building tips so I can eventually get around to building something foamy and awesome.
     
  13. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Hum hmm...
    Here we are.

    Dear users from the entire world,
    When you watch a video movie, le last ten minutes are always the same : a black screen with a OST's main title, and a three miles long list of names of peoples that did a thing for this movie. From the realisator to the restroom guy #4, everybody has his name minutely put down. It's shamely boring, and incredibly useless since meenwhile the whole audience is already trying to find back where they've parked their car (and they miss the short hang-up at the very end), BUT credits and casting remains at the end of every movie because it's imposed. And there is a reason why.:confused

    TheRPF is a nice and bucolic place, where we can learn, expound, watch, submit, exchange and share knowledge. We often swagger, sometimes learn, and rarely inquire (re-sort on your own), because it's obviously the way a common forum works well.

    It must not be a reason to share all and everything, of course, and we have to keep in mind that, just as in a movie, some support and knowledges would not even exist wihtout long time contribution and devotion of REAL people, who happened to spend non-stop long months elaborating concrete and accurate ressources. (And to share it, of course, since an unshared ressource is not a ressource). We can definitively not crop up and claim "have a look at the nice JFcustom's tower I buit out of matches in two hours only", when it remains in fact an Eiffel tower which I moded original plans to use maches as main material insted of steel.

    Around here we do not deal with credits. Those who have tryed can't talk about anymore.:love
    That's why I should have renamed each file inside my *.rar befor sharing it whith you. Just like at the end of movies. It can seem also boring and useless, but it has to be seen as a moral obligation for each of us not to disassociate a creation and its creator. And remember nobody can pretend having invented the Purpule Pig only by painting a pig in purple. :confused


    But the worse is yet to come.:behave

    Just like you I downloaded files, revise them for my own use, bought foam, and built a suit, wihtout asking whatever to anybody. That's fine, TheRPF is here for that too.
    BUT ! after having been asked for, and when my turn finaly came to share these modifyed files, I quickly made a zip without inquiring about protocol nor permission from nobody. For an Eiffel Tower id would have been different, G.Eiffel died in winter 1923. But robo3687 and darkside501st did not. And as such, they legitimately want to know what happend to the original files they've shared, what do these files become between our hand. Especially they may want to be notifyed when their files are tunned, and above all they may want to retrive and check new packages in order to allow or no their public distribution.

    :cry Oh remorse, remorse, robo3687 for Iron Man Mark IV and darkside501st for Iron Man Mark VII, please be kind enough to forgive an irresponsible and careless frenchie who stole your awsome 3D models you spent a crazy long time to complete, a single guy that finaly did only try to make your work more reachable for most of us, those who can't aford spending half a year to build a cosplay. I apology for all the inconvenience, and promise that by now I won't swift away official protocol channels. But please, it does not seem that users on this thread would like me to stop posting tips I use, nor files I mod. Just let them keep using your work with tips I explain, and allow an access to these files. The more your work will be used, the more consequentialy will grow your notoriety.:cool

    Well, files are renamed, creators credited, humble apologyes done... can we please go on now and proceed to dl-links resurection ? Users are queuing... :darnkids
     
    Last edited: May 27, 2012
    Arc Nineoneone likes this.
  14. darkside501st

    darkside501st Sr Member RPF PREMIUM MEMBER

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    JFCustom... that was quite a grandstand. Listen, I personally think it is no big deal to modify an existing file (in this case a pepakura file). I did not know anything about your work on this until you contacted me at the request of the RPF Team. So long as you are not claiming these files were developed by yourself then I do not see any problem with you sharing your building techniques and your foam templates of my pepakura files. I do appreciate you putting my name back on the files as I would like people to know where they originated from.

    I think it is great that you have taken such a common sense approach to foam building, modified the templates to reflect that, and then shared your build with the other members here on the RPF. That is what this site is here for after all. So I say share on. Live and learn. Now you know one thing that will get you a slap on the wrist so to speak. :rolleyes
     
  15. longlenium

    longlenium New Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    nice work jfcustom
    however the link is not working!!! =(
     
  16. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Now it is.
    Thanks Darkside501st :thumbsup
     
  17. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    EDIT : content moved to first post
     
    Last edited: Aug 22, 2012
  18. Jonny

    Jonny Member

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    191
    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    That's a genius way for creating rotating joins. I especially like the fact that the botte neck is quite wide so it's less likely to rip the foam.
     
  19. docholiday78

    docholiday78 Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Great tips! you know how long Ive been researching to find a better joint solution other than rivets. And you have done it and with simple objects i wouldve never thought of using. Put it on my mark VII leg now it bends perfectly. Thanks for sharing
     
  20. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    EDIT : content moved to first post
     
    Last edited: Aug 22, 2012
  21. jayjayn

    jayjayn Well-Known Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.


    WOW ARE U SERIOUS!! great idea man!, i've been trying to think of alternative to the chicago screws that tend to always come off the glue or unscrew them selves some how.

    Those rivets on your thigh to shin points how are the pivoting? you must be using a longer post right?

    LOVE THE TIPS.. definitely gonna help a lot!
     
  22. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    EDIT : content moved to first post
     
    Last edited: Aug 22, 2012
  23. CommanderNiyic

    CommanderNiyic New Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    This is an awesome build! I'm planning on using your modified files to make a foam/aluminum Mark VII, but the .rar files you've posted don't want to open in Pepakura. Do you have another link or method of viewing and printing? Thanks, and great job!
     
  24. TheNickFox

    TheNickFox Sr Member RPF PREMIUM MEMBER

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    RAR files are a type of archive file, like a zip file, designed to contain and shrink the file size of multiple or large files.

    In this case the rar, when unrarred contains ALL of the PDOs for this suit.

    A quick Google search should turn up free software to unarchive Rars.

    -Nick
     
  25. Ikariya

    Ikariya Well-Known Member

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    567
    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Thanks for simplifying the pattern for foam. Foam really takes curves nicely and doesn't need any flattening out! I will probably use these... =) Thanks to all involved making them.
     
  26. AkiBadtrip

    AkiBadtrip Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Awesome tips! Would try Making good use of them on my next build. Love the detailed stuff on how to Glue parts!
     
  27. teragon

    teragon Sr Member RPF PREMIUM MEMBER

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Those are really great ! Thank you !
    Although I've been playing around with the lower forearm assembled in paper, and in its original size, it is quite short, and to get the right length, it would need a +20% scale but then it's too wide... I guess 10% would do, but still a bit short as it should go all the way up the elbow (the upper part of the gauntlet, that is)... Anybody else have this problem ? Or is it just me who has long arms ?
    Funny thing is the rest of the parts seems to be the right size without modifying anything even if I have not assembled them nor print them, I just compared the "assembled size" Pepakura Designer gives to my measurements.
     
  28. jamesrickards

    jamesrickards Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Awesome tips...LOVE the cola bottle. Will definitely be using that in my WARMACHINE suite!!

    Cheers:)
     
  29. animefan

    animefan Sr Member RPF PREMIUM MEMBER

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    thanks for the files, they should help out for my mk 7
     
  30. Dont Panic

    Dont Panic New Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Very cool, I think I might give this a shot.
    Few questions: Any advice on scaling your particular files? I'm 6'7 and 190 lbs, so I'm finding it a bit tricky to get a good fit for many parts.

    What thickness of foam are you using?
     
  31. Shades

    Shades Well-Known Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    @ JF-

    How do you add the tabs in pepakura? I do custome unfolds all the time, but never play with add tabs back in. This could prove very useful.
     
  32. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Hi guys,
    well, these files are scaled quite strictly the same than those from this thread : Darkside501st's Iron Man Mk VII pepakura files because I've only rearranged the edge combinations of most of the pieces for each part of the armor. My advice is : scale it the same as if you were scaling Darkside501st's pep files, besause they are also stemmed from the single same Darkside501st's 3D model.
    I use rolls of 6.5mm thickness, that I can more or less harden with a light or heavy coat of Sikafill. Or Rubson. Or every similar coating that is called upon sealing roofs from rain.

    One of the main plus we have to build with foam, in my opinion, is that once done we can easily cut or add foam pieces here and there and around, in order to fix these kind of issues.



    In fact, all the pieces of the object displayed in the half left of Pepakura are necessarily present too on the sheets laydown at the half right. If you do not see them, it's often because they have been aggregated outside of the white area. Scroll and you'll find them. Or use 'cut/join' function. Or undo/redo unfolding... You can't miss them. Anyway, you can't add a piece that does not already belongs to the (undolded or not) object.

    [​IMG]

    1- 3D object
    2- unfolded pattern
    3- assembled foam

    I don't add anything, I simply re-use unused pieces.

    Have fun.
     
  33. itsaplane

    itsaplane Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    I love you. Thanks for this.
     
  34. Guri

    Guri Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    I'll likely never make an Ironman costume, but this tutorial is AWESOME for tips on how to think through foam/armor/3d pieces.

    The smilies crack me up too. :)
     
  35. Dont Panic

    Dont Panic New Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Thanks for the info, I think I've tracked down some thin enough foam, can't wait to get started. I've been poking through your file, and had a few more questions. Some of the pieces have what look to be like large flaps on the edges, some times sperated by evenly dashed lines, sometimes not. Are these "flaps", for lack of a better work, supposed to fold a certain direction to help create a raised/lowered area, or am I misinterpreting this?
     
  36. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    You're in the truth.
    I've left some important lines where it was important to leave some lines. A large part of pep-foaming is based on this :
    [​IMG]
    You'll often have to give a shape to a single piece of foam in order to decrease the amount of seams.

    Let's play with a MKVII handplate : [​IMG]



    _
     
  37. Dont Panic

    Dont Panic New Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Thanks, that drawing was really helpful. I was wracking my brain trying to figure out how to make small cuts on the underside of the foam to bend it to get the step... Now it makes much more sense.
     
  38. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    The main two usefull ways I use to make steps :

    [​IMG]

    Here's drawn a third method to realize a half-step. Usefull for thicker foam, or for detailed areas such as helmet or gloves, neck, ARK area...

    [​IMG]
     
    Mig407 likes this.
  39. MisterTV

    MisterTV New Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Thank you for your help! And I can not wait to see your MarkVII!!!?
     
  40. Jonny

    Jonny Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    JF, got any tips for cutting the triangle out for the mountain fold without going through the other side? I can see people having trouble keeping the depth consistent.
     
  41. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    I must confess it did never happened to me, which explains my lack of tip about that. Anyway, if cutting at once each side of the triangle turns to failure, they may try to cut concentric triangles, starting with a small shallow one, and going larger to deeper until almost reaching the other side. The way a beaver would do... :)

    Edit : conscientious that I am, I've just tryed out. At first I've sharpened my knife (ALWAYS resharpening, as soon as you feel that you don't cut warm butter), I apply my thumb on the side of the blade AND on the foam simultaneously, so as to prevent the blade from pearcing through it. My inch acts as a depth stop.
    Never had problem.
     
    Last edited: Jun 7, 2012
  42. mizuno hadouken

    mizuno hadouken Well-Known Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Any updates?
     
  43. eldonnaty

    eldonnaty Active Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Sir I Say sir i Tip My Hat To You For making this Much Easier for some of us thanks!!
     
  44. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Given that I did not had time enough to even plug my brand new glue gun yet, it's not too late to change my mind and select an other suit. I've just unfolded the foam version of Iron Man Extremis Pepakura Files and will build this suit instead (or at first).
    [​IMG]

    And anyhow still in 4 days.
     
  45. chamuco110

    chamuco110 Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    Hi! JF custom, i wonder if you are going to share, your extremis foam version files, i will appreciate if y ou do so. Best regards!
     
  46. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : FOAM Iron Man MkVII within 4 days.

    The .rar package is in the first post of the link above.

     
  47. chamuco110

    chamuco110 Member

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    Re: Speed-building files'n'tricks : 4 days FOAM Iron Men.

    Thanks for the files JFcostume and EoS.
     
  48. jayjayn

    jayjayn Well-Known Member

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    Re: Speed-building files'n'tricks : 4 days FOAM Iron Men.

    thx a lot for the foam mod files, btw the link for the extremis on the first post is incorrect btw
     
  49. JFcustom

    JFcustom Sr Member

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    Re: Speed-building files'n'tricks : 4 days FOAM Iron Men.

    Oops :\

    ...

    Fixed :)
     
  50. msleeper

    msleeper Sr Member

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    Re: Speed-building files'n'tricks : 4 days FOAM Iron Men.

    This is such a great thread! Thanks so much for sharing your knowledge, JFcustom. I think what a lot of foam threads forget to mention (that this thread is dedicated to) is to not blindly follow your templates and to use your brain when cutting, gluing, and building your foam suits. The templates make things easy, but you still need to think about how to put it all together.
     
    AnnaG likes this.

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