Mr. Freeman's HEV Suit - First Time Build

Discussion in 'Replica Costumes' started by Insane muadib, Apr 27, 2012.

  1. Insane muadib

    Insane muadib New Member

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    Hey folks
    I am working on getting into the prop-making and costuming hobby/profession, and I'm putting this here to get some advice from you folks who have so much experience.
    To start with I am posting at this stage because I have come upon a issue that I am not sue what to do about, but here is my progress so far.

    The overall purpose of this project is to produce a Silicon Mold that I can cast multiple fiberglass copies of this suit out of. This is because I want to produce at least 2 of these (one for me, one for a Child's Play auction in July) and I will be following a method learned from following Volpin's website.

    To start I had some issues working from the wonderful art images that exist of the HEV suit as they don't all keep the same scale for the suit. So I decided to work from the PEP model done by Nugget, Loess, and (Null).exe. I rescaled many of the pieces to the proper size for myself. I am about 6'2" and round 190lbs for reference to you folks, and here is what I got to in the end.
    [​IMG]
    Distal Arm
    [​IMG]
    Upper Leg
    [​IMG]
    Torso Back
    [​IMG]
    Torso Front
    [​IMG]
    Lower Leg
    [​IMG]
    Upper Arm
    From this stage I went and produced some blueprints from the PEP pieces that I then transferred to MDF. I then went and cut out the MDF form for the lower arm only to realize I was doing it wrong. I was trying to get far too much of my detail from the foam and ended up just getting a lumpy mess.
    [​IMG]
    This is what the frame looked like originally.
    I ended up tossing out that frame after building it with pink foam and Smooth-cast 60D.
    Then I went on to cut out the Upper Arm and Lower leg from 1/2" MDF. to assemble them into a proper form.
    [​IMG]
    Following that I used pink foam to build p the volume of the form and then carved it down using a coping saw into the general form. Then I sand it down with my radial sander to get a nice rough to work from.
    [​IMG]
    This is a view of the upper arm before I went to town with the coping saw and sander. Following that I threw some Smooth-Cast 60D on it to give it a nice durable shell and protect it from the next step. But this is where I ran into a odd issue.
    [​IMG] View 1
    [​IMG]
    View 2
    The above piece is covered with a single pass of Bondo. In view 2 you can see the issue. There is a bubble that was formed with the Smooth-cast. I can tell that this is formed by the reaction from the Resin, but I am not sure if this is just a mixing error on my part. Does everyone have this issue?
    Here is a close-up of the area:
    [​IMG]
    The upper portion looks the way it does because I attempted to cut it away with my box cutter.
    All right that is all for this week, but I will probably post my weekend progress on Monday night though, hope you all like this and follow along.
     
  2. crabra comander

    crabra comander Sr Member

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    I think bubbles are common place. Just sand and fill holes, sand and fill. At least I think thats right. I'm still amateur.
     
  3. Insane muadib

    Insane muadib New Member

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    I checked with others and Volpin agrees with you. What he seems to think is that it is moisture trapped in the foam that reacts and causes it to bubble up, and the only way to fix it is sanding after the fact.
     
  4. Insane muadib

    Insane muadib New Member

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    Mr. Freeman's HEV Suit (5/6 Update)

    Update 5/6/12
    Hey Folks sorry about the Hiatus for a week. The work for my Master's got a little out of hand and I needed to catch up on that.

    Not much work got done in the past week, maybe like 6 hrs of design work and 4 hrs of cutting, but here is what I've got now.

    [​IMG]
    Overall Progress of the Project.
    [​IMG][​IMG]
    2 Views of the Thigh pieces.
    [​IMG][​IMG]
    Front/Back view of the Torso.

    So that's all I've got as far as a update for this week. Next week's update should be a lot more exciting as I will have place all the pink foam and should be a good way (it should start to look roughly accurate) into the carving/modeling of the surface.

    So my questions for the week are:
    • Anyone got a good match for Dr. Freeman's Glasses?
    • Any recommendations for the undersuit?
    • Any idea what to do about the boots (I Have 0 Experience in Footwear)?

    Thanks for Reading Folks. Cya next week.
     
  5. SneezyDinosaur

    SneezyDinosaur New Member

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    May i ask where you got those PEP files?
     

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