The Mando Project (S.A. Blaster, Metal Beskar Ingot and I guess maybe the whole darn suit...!)

[JOATRASH FX]

So, like many of us, The Mandalorian has me more excited about Star Wars than I've been in a while. And even though I'm behind on X number of projects, I gotta do at least a couple things from the show and will be updating this thread with them as I go.

I'm fighting the urge to rush things. As with most of the stuff I do I'm gonna take the time I need- being weeks or months if I that's what it takes to get an accurate final piece. We'll see how many pieces I end up doing!

I've made a start on his sidearm, and am noticing some things that aren't directly apparent, but at the time of writing this the 3d model isn't worth showing. (I basically spent the entire weekend assembling reference to work from, including doing a lot of color de-grading and things to analyze available images.)

However, I have made a bit of progress on the Beskar ingot- so much that I have a rough low-res prototype printed, with a higher detailed one in the works. I was able to use the method I developed for a couple other projects, similar to photoscanning, to transfer details directly from the screen prop onto my 3d model, which preserves and replicates a lot of details almost exactly- far more that what would be possible just hand-sculpting.

In the show, it looks like we saw a couple versions of the prop- one just for show and one for melting. The latter one seems to have been made of pewter and has a bit of a texture to it, while the former is smooth. I have some ideas of how they did the wavy pattern... some have mentioned hydro-dipping and maybe that's what was done, but for the fact that it'd be impossible to get more than one copy exactly the same, and the waves seem a little too thin and perfect. (Dipping tends to be more chaotic.) I have some other ideas that I might explore.

I'm also talking with a metal foundry about casting some in aluminum!

In this first version, I transferred all the details- wavy pattern, Imperial stamp (and indents on the back) but I'll probably move onto a version without the wavy pattern.

Some photos and a video of what I have so far.

Near-final cast aluminum Beskar with pattern and stamp (keep reading for progress):

Early tests:

This is just the raw print, painted with Citadel (Games Workshop) "Lead Belcher", which is a great metallic base for a lot of things.

I kept the billowing surface

More as soon as I have something to show!

 

[JOATRASH FX]

I've got a smooth ingot printing right now.


Got word from a foundry I've had discussions with before and all signs point to them being able to do this for me at a reasonable (well, for the number) cost. I thought about maybe casting it myself in pewter, but it's almost impossible to get a clean enough surface that preserves details crisply.

Back to work on the blaster...

 

[JOATRASH FX]

Kinda funny how things develop sometimes. When I got home last night I had a "screw it, lemme try something" moment while tinkering with the ingot. A short while later, after several simultaneous attempts at dealing with the antics of a crazy kitten, I had this:

Keep in mind that this is VERY roughly done. The color needs work and I only had a brick with the lines engraved handy (the smooth one was still processing) so you can still see the grooves (which kinda look like wrinkles) but overall I'm pleasantly surprised with this. I've confirmed that they used different ingot props in the episode (at least 3, I think) and they all have a different wavy pattern on it. This supports the idea that they were hydrodipped, after all, though I'm still not completely convinced. (The pattern still looks a little too sharp to me for dipping, but I'm going to give that a try too, just out of curiosity.)

Still a lot of tweaking and testing to do, but I think I'm going to abandon the "engraved pattern" route and just keep the screen-transferred Imperial stamp. At first I was thinking that transferring the pattern would make it "feel" more authentic since it was directly from the prop, but it's not gonna look right. Adding the pattern later will, and keeping the stamp, which was also transferred from the real prop, will be enough for me.

More later. Cheers everyone!

 

[JOATRASH FX]

Ok, so here's the lastest ingot test:

After fiddling around a lot with a from-scratch drawn pattern, I decided to go back to the original again and see if I could replicate it with more fidelity intact. After a helluva lot of tweaking, here's the result. I'm still refining the intensity, but I'm happy with the progress.
I might do some changes to the stamp... not sure yet. (It looks a little big BUT after applying perspective correction and compensating for lens distortion, it matches up fairly well in size. The photo actually shows two different prints I did, each with the screen pattern applied and a slightly different transfer of the stamp.

 

[brandomack]

Final version (I think) of the textured ingot. I've got a smooth one printing right now.
View attachment 1085179

Got word from a foundry I've had discussions with before and all signs point to them being able to do this for me at a reasonable (well, for the number) cost. I thought about maybe casting it myself in pewter, but it's almost impossible to get a clean enough surface that preserves details crisply.

Back to work on the blaster...

I could cast these in pewter for you with details intact.

 

[Kylash]

So is that pattern in the sculpt or a transferred image? I’m not clear on that. Either way it looks amazing!

 

[JOATRASH FX]

So is that pattern in the sculpt or a transferred image? I’m not clear on that. Either way it looks amazing!

The first couple of tries (pictured above) I started to put the pattern in the sculpt, but after repeated close scrutiny of the different copies on screen (which have different patterns), it's clear that the real prop has the pattern as a transferred image, so that's what I ended up doing too.

(The idea of having it as a relief in the sculpt is kinda neat, because it makes it more "real world" like Damascus steel (which has a similar pattern, but with lots of "jagged egdes") but my goal is almost always to get as close to the actual prop as possible.

The differences in patter of the screen props kinda suggests they were hydrodipped, but for my reservations about the sharpness of the lines.

And thank you! : )

So, when will there be a run? In for a resin one painted like that.

There's already a run for metal copies in the junkyard and I'm talking to another (well-known) RPFer about doing them in resin.

I could cast these in pewter for you with details intact.

I thought about that, and have actually done a bit of pewter casting waaay back. Around ten years ago I did a run of Jubal Early pistols from Firefly in pewter. My main reservation to pewter is that getting a smooth surface without any pitting is hard unless you're doing something like spin-casting. But admittedly, I haven't done a lot of it. We can certainly talk about it, but it might be a problem sending blocks of heavy pewter back and forth across the Atlantic. : )

 

[JOATRASH FX]

A tiny bit of progress on the blaster but I've mainly been doing the ingot. I've kinda restarted the frame three times already, and this is still in the "blocking out" phase.

Looks like the grip frame will be separate from the receiver so that I can print them without having visible seams (except where there are supposed to be seams). Receiver will be split into asymmetrical halves like the real prop seems to intend. Grips will of course be separate. Slide frame, rails and sights will be as well. Barrel will be a steel or aluminum tube. I'm also tinkering with an idea of how to screw the receiver halves together in case batteries need to be replaced.

 

[BastianEstrella]

I don´t know if you´ve considered this, but it could be achieved by laser engraving, we have a pretty good engraver here at work that might be able to do the job perfectly, if the color needs to change it could be painted since the engraver leaves a decently deep pit that can be painted easily.

This is a sample of a stainless steel piece and the colors that the engraving leaves, no paint.

 

[JOATRASH FX]

I don´t know if you´ve considered this, but it could be achieved by laser engraving...

D'oh, I can't believe I forgot to update this thread!

I thought about engraving, but it wouldn't end up being screen accurate- for one it's hard to get the "organic" look of the stamp (which I transferred with all the asymmetrical details intact) and also, the Beskar pattern isn't just black/white but has subtle variation in opacity. It's the reason why I opted to skip transferring the pattern as a relief onto the face.

After having the ingot cast, I ended up with this look:

I'm also quite a bit further along on the blaster:

The entire slide/top area is still far from done, as are most other details but I've got the rough stuff blocked out. Not too long until I'll be able to start hollowing out and breaking it down into many parts. (I might ask the foundry that cast the ingot to also cast the receiver halves of the blaster.)

 

[propcollector]

What dimensions are you using on the beskar bar??

 

[JOATRASH FX]

In situations like this, I mainly compare details to other real-world pieces in various shots from the show or movie, then recalculate and extrapolate values, but also I occasionally do gauging of some things "by eye". It's surprising how close you can get on some things by learning what "looks right".

 

[Scarecrow Joe]

Watching thread intently....

 

[JOATRASH FX]

Finally, a tangible update. Here is the first test print I did of the grips!

These were a test to gauge size and how deep I want the wood grain pattern to be. (It feels kinda odd to be adding lines in print for a change, when you're usually trying to get them glass smooth. I just did a wash over the raw print so that I could see how deep the grooves were. Will probably make them deeper, so that they take washed of paint better.

I printed the grips and part of the grip frame and when I held them in my hand they felt much too small, even if this is supposed to be a Mauser-like blaster. Turns out the model was around 12% too small, if using the Bergmann as a rough estimate. I initially based them on measurements I found online (somewhere) of the Bergmann inspiration pistol, that must've been incorrect. By stroke of luck, I discovered that a local museum actually has TWO copies of Bermann pistols and was able to use them to recalculate some measurements. (They don't have the "correct" model, but I'm guessing the trigger well is the same size on all of them so the current size I have now feels more right.)

Today, I was getting close to having a more or less finished exterior, but some details on the slide bugged me so I've restarted that part from scratch for like... the fifth time now.

 

[Scarecrow Joe]

Those grips look very nice!

 

[JOATRASH FX]

Almost done with the slide. It looks simple at first glance, but damn they put a lot of small details into it to make it look like cast steel. You can't really see the subtleties in this render, but most of the edges are "soft" as if the steel has been worn down, the slide is asymmetrical, parts are just very slightly misaligned. It all adds to why the blaster looks so "right" in Star Wars canon.

At the moment, I have the portion in white running in the printer as two parts. (The "brass" ejector block is a separate piece.) Dending on how it turns out, I may also separate the rear sight, but I don't think it'll be necessary. Next I'll go for detailing the receiver.

 

[JOATRASH FX]

OK, so the first printed detail piece is here! Turned out pretty OK, maybe some things to tweak here and there and I might still have the sight block separate. I really want it to look like it was put together from many parts and not printed in one or two pieces.

Still surprised at how small the part is, but everything suggests it's accurate in size- it's just a very slim-looking blaster overall. Like I mentioned before, I left the brass block separate- makes it easier for painting, or in case I want to have that piece in real brass later. I'll have an aluminum barrel running through the whole thing to make it more durable.

And in case anyone is interested, here's one of those 'fanatical' detail things I sometimes go on about. After looking at countless screen grabs and still-framing through footage to study light movement over the surface, I concluded that the absolute back end of the slide is slightly thicker than where it extrudes into the wider section. Check the circled areas in the photo. Normally, you'd expect an area like that to taper off in all directions, not get thicker! (It also only appears to be that way on one side.) At first I thought maybe it was just the angle of the short sides that changes, causing an optical illusion, but it doesn't look like it. Now, I may of course be wrong about this detail (and I'd kind of like to be, because it would look better tapered out), but all the reference I've looked at suggests this is how it is.

(This is straight off the printer... support points haven't been sanded down yet.)

 

[zsherman]

OK, so the first printed detail piece is here! Turned out pretty OK, maybe some things to tweak here and there and I might still have the sight block separate. I really want it to look like it was put together from many parts and not printed in one or two pieces.

Still surprised at how small the part is, but everything suggests it's accurate in size- it's just a very slim-looking blaster overall. Like I mentioned before, I left the brass block separate- makes it easier for painting, or in case I want to have that piece in real brass later. I'll have an aluminum barrel running through the whole thing to make it more durable.
View attachment 1092725

And in case anyone is interested, here's one of those 'fanatical' detail things I sometimes go on about. After looking at countless screen grabs and still-framing through footage to study light movement over the surface, I concluded that the absolute back end of the slide is slightly thicker than where it extrudes into the wider section. Check the circled areas in the photo. Normally, you'd expect an area like that to taper off in all directions, not get thicker! (It also only appears to be that way on one side.) At first I thought maybe it was just the angle of the short sides that changes, causing an optical illusion, but it doesn't look like it. Now, I may of course be wrong about this detail (and I'd kind of like to be, because it would look better tapered out), but all the reference I've looked at suggests this is how it is.
View attachment 1092726
(This is straight off the printer... support points haven't been sanded down yet.)

Loving on this. Would love one when you’re done.

 

[zsherman]

OK, so the first printed detail piece is here! Turned out pretty OK, maybe some things to tweak here and there and I might still have the sight block separate. I really want it to look like it was put together from many parts and not printed in one or two pieces.

Still surprised at how small the part is, but everything suggests it's accurate in size- it's just a very slim-looking blaster overall. Like I mentioned before, I left the brass block separate- makes it easier for painting, or in case I want to have that piece in real brass later. I'll have an aluminum barrel running through the whole thing to make it more durable.
View attachment 1092725

And in case anyone is interested, here's one of those 'fanatical' detail things I sometimes go on about. After looking at countless screen grabs and still-framing through footage to study light movement over the surface, I concluded that the absolute back end of the slide is slightly thicker than where it extrudes into the wider section. Check the circled areas in the photo. Normally, you'd expect an area like that to taper off in all directions, not get thicker! (It also only appears to be that way on one side.) At first I thought maybe it was just the angle of the short sides that changes, causing an optical illusion, but it doesn't look like it. Now, I may of course be wrong about this detail (and I'd kind of like to be, because it would look better tapered out), but all the reference I've looked at suggests this is how it is.
View attachment 1092726
(This is straight off the printer... support points haven't been sanded down yet.)

I tend to wonder how they went about making this one? I know it’s not beyond Hollywood to take a super rare item and modify it, using off the shelf current military parts, like the rear sight assembly and the attachment rail, but do we think this thing was rendered in 3D, printed and cast? And if so, was it cast in metal?

I honestly haven’t looked closely enough to see if the hammer falls when he fires or anything. I’m sure, like every other prop, there’s a hero and a ton of stunts.

Is there an airsoft or metal replica of this piece somewhere? Thoughts? Not to at ALL take anything away from the AMAZING WORK that is being done here (cuz I totally want one). Just wondering.

 

[JOATRASH FX]

I tend to wonder how they went about making this one?

Right now, there's no doubt in my mind that they modeled it from scratch and 3d printed uit, using the Bergmann as an inspirational base, nothing more. Beyond the overall look, virtually nothing on the Mando blaster matches the Bergmann- every little shape and detail is different somehow. (That's why I'm not really even looking at the antique pistols when doing this.) They may have cast one in metal, but there's no real point to it for filming... paint has come so far now that you don't need real metal for a filming prop unless you really want the actor to feel he weight.

If you look closely, you can see parts broken off the blaster in some scenes!

I honestly haven’t looked closely enough to see if the hammer falls when he fires or anything. I’m sure, like every other prop, there’s a hero and a ton of stunts.

From what I've seen, it doesn't move. If I remember correctly, there's a behind-the-scenes clip with Mando walking and firing... you can see his finger move but the hammer is static. (I also haven't been able to really verify if there's a hole for the firing pin of the hammer on the receiver or not.)

I've been thinking of maybe having a moving hammer of some kind... but I'm not sure I'll bother if the screen gun doesn't.

Is there an airsoft or metal replica of this piece somewhere? Thoughts? Not to at ALL take anything away from the AMAZING WORK that is being done here (cuz I totally want one). Just wondering.

I haven't seen an airsoft or replica in metal. If there were an airsoft of the Bergmann it would be kind of pointless, at least to me, for the reason above... nothing on the Bergmann matches the screen gun. I'm toying with the idea of having the receiver cast in aluminum, or having the muzzle machined, but I don't know yet, but it'd be costly. (And if you really want one... check the junkyard! ; ) )