My Clone molds -UPDATE 8-7-06

Discussion in 'Star Wars Costumes and Props' started by Rodann, May 27, 2006.

  1. Rodann

    Rodann Sr Member

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    Update 8-7-06

    I've finally had time and energy to finish what I started. Or is it finish starting what I started?

    I cleaned up my shin, calf, and knee molds, and I'm VERY happy with what came out of the oven.


    For my custom Mando. I sold my 1960's Alpine motocross boots, so I needed something. And I got to use my old Clone "shoe covers". Hey, Dengar can have TK shins, right? ;)
    [image]http://images.andale.com/f2/115/106/2379504/1154011978286_Legs_003.jpg[/image][image]http://images.andale.com/f2/115/106/2379504/1154022305602_Legs_002.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1156839412801_Legs_001.jpg[/image]


    My Bly shins and knees, too:
    [image]http://images.andale.com/f2/115/106/2379504/1156537398451_Legs_005.jpg[/image][image]http://images.andale.com/f2/115/106/2379504/1155082274310_Legs_004.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1153525802615_Legs_006.jpg[/image][image]http://images.andale.com/f2/115/106/2379504/1155986663487_Legs_008.jpg[/image]
    http://images.andale.com/f2/115/106/237950...89_Legs_007.jpg
    http://images.andale.com/f2/115/106/237950...4_Legs_0010.jpg

    Details:
    [image]http://images.andale.com/f2/115/106/2379504/1157005111120_Legs_0012.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1153769767610_Legs_0015.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1154123117310_Legs_0014.jpg[/image]


    Molds and stuff:
    [image]http://images.andale.com/f2/115/106/2379504/1156210202248_Clonetrooper_molds_001.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1154230140217_Clonetrooper_molds_002.jpg[/image]
    http://images.andale.com/f2/115/106/237950...r_molds_006.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_007.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_003.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_004.jpg
    http://images.andale.com/f2/115/106/237950...s_knees_002.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_005.jpg
    http://images.andale.com/f2/115/106/237950...s_knees_001.jpg

    I pulled a few sets of each, and made another knee mold so I can pull two at once. Just makes more sense than wearing out the one mold.

    I've started these 6 pieces first, as an "upgrade kit". Because for years now, I've had (ahem) "inferior" shins. ;)


    .................................................................................................................

    I FINALLY started sculpting my own armor pieces today. After building a vac table in October. :lol

    I started with clay, the first of several stages. The pieces I need to focus on for upgrade, are the all leg pieces and the backplate. So far, I've got the mold for the front shin, back calf, and knee mostly done today. It was fun, and I really enjoy working with clay. Crap, I may have the back redone by tomorrow.

    Next to some older armor pieces, for comparison:

    Shins:
    [image]http://images.andale.com/f2/115/106/2379504/1149759779035_Thighs_003.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1149275760193_Thighs_002.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1150023591435_Thighs_001.jpg[/image]

    Knees:
    [image]http://images.andale.com/f2/115/106/2379504/1149293015920_Knees_001.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1149773674481_Knees_003.jpg[/image]

    When the clay hardens, it will crack and shrink. I'm planning on that, because I have a few things I'm going to try.
     
  2. DarkLordSalvo

    DarkLordSalvo Well-Known Member

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    You might have an undercut with the scallop on the back of the shin. Hard to tell but it looks iffy. Other than that you're off to a great start.
     
  3. Rodann

    Rodann Sr Member

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    Yeah, thanks- that's getting taken off, once it sets up some more. Still too wet for government work. I had planned on sanding it, after the plaster copy of the mold.
     
  4. DarkLordSalvo

    DarkLordSalvo Well-Known Member

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    I figured you'd catch it but just in case, wanted to point it out. :thumbsup
     
  5. GundamZeppelin

    GundamZeppelin Sr Member

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    thats looking good :thumbsup :thumbsup
     
  6. Reactor drone

    Reactor drone Well-Known Member

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    Very nice.I usually work in plasticene so I don't have the drying out problem...then again I can't sand it smooth like you can with clay.

    Also since you can't vacform straight over plasticene I've taken alginate moulds off my sculpts and then made Hydrocal positives that I can then vacform.
     
  7. Darth Kahnt

    Darth Kahnt Sr Member

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    Looking good so far.
     
  8. Rodann

    Rodann Sr Member

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    Thanks.:)

    I cleaned up the edges a bunch, and took down the sharp scallops, since it had gelled some more. One thing you learn as a machinist- it's always easier to remove material, than to add it.;) With the edges down, that heel scallop doesn't look crooked like it does in that pic.

    I'm tired. :lol Standing hunkered over my kitchen table most of the day, my back is killing me, my feel hurt, and I have a killer headache. But hey, I can't complain. :p
     
  9. blufive

    blufive Sr Member

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    Nice job, Jim. Feel free to send samples to me.

    :p
     
  10. Trooper TK409

    Trooper TK409 Well-Known Member

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    Wow awesome Jim. I had no idea clone armor was being sculpted in my own backyard. I'll follow your progress with much interest. :)
     
  11. uscm buzz

    uscm buzz Well-Known Member

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    boy I could sure use some test rear shins for an set of armor I sold a guy.. would love to get him just something to use.. the armor wasnt great quallity.. so he would take whatever. and a but plate too.. , oh and the hand armor.
     
  12. Rodann

    Rodann Sr Member

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    Just the legs and back for now.:) I'm still just upgrading, but I may get to the other parts by Dragoncon. Maybe sooner. I wasn't PLANNING on doing all of it originally, but I think I might. And since I opted out of the KAW group, and settled for two chest pieces, I don't need that one for now. If I did sculpt a chest piece, it would have to be a little smaller than his.

    Doug, who is Samples? Do I know him? ;)
     
  13. Rodann

    Rodann Sr Member

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    Here are my first pulls. Second stage complete.:D I'll give you three guesses where I got the plastic. :lol Don't laugh. I had to modify one of my frames for smaller material, but it worked for what I need. The clay was cracking, so I hurried up on the second stage. The paint on the signs really messes with their ability to melt evenly, and I don't recommend using them for actual PARTS, but for just pre-mold pieces, they're fine. You can see where I rounded the calf scallops, after they set some more.

    First Pulls:
    [image]http://images.andale.com/f2/115/106/2379504/1149968778147_Clone_Armor_My_1st_Pulls_001.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1147384911527_Clone_Armor_My_1st_Pulls_002.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1147798721104_Clone_Armor_My_1st_Pulls_003.jpg[/image]

    Here's my work center. :D I really get a kick out of people who claim that someone can't do molding, forming, or (gasp.) recasting, by saying their "workshop is their kitchen". Where, exactly, WOULD it be? The bedroom?:lol
    [image]http://images.andale.com/f2/115/106/2379504/1148043821482_Clone_Armor_My_Vac_001.jpg[/image]

    And on a slightly unrelated note, here's my old and new Chest Armor:
    [image]http://images.andale.com/f2/115/106/2379504/1150271548345_Clone_Armor_My_Chests_001.jpg[/image]
    Not made by me, though. I'll probably use pieces of the old chest to bulk up the backplate, once I get started making a new one. And those shoulder straps are still good.
     
  14. GeneralMayhem

    GeneralMayhem Sr Member

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    Outstanding work. Looks like you're off to a good start.

    :thumbsup


    ~ GM
     
  15. Boba Frett

    Boba Frett Sr Member

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    Looks like you are off to a nice start, BTW I have done the exact same thing in the past using signs to do test pulls :)
     
  16. Rodann

    Rodann Sr Member

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    They suck, don't they? :lol

    I can't wait til I get some REAL plastic after I'm done sculpting.

    The solid plaster casts of the test pulls are done. Now I'm starting on my thighs. I'm actually going to skip the clay process with these, since I have already heat-formed and altered my old thigh pieces so much. There's none of their original shape left to them, since they were so inaccurate to begin with. But they'll provide the foundation to work with. Once I cast those, I'm going to lengthen and resculpt them some more. Like the poorly made undersized shins next to my shin molds, they will be completely different. Hard to believe these pieces once passed for Clone armor.
     
  17. Boba Frett

    Boba Frett Sr Member

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    <div class='quotetop'></div>
    Yes they do :)

    I will be keeping my eye on this thread, the work you have already done looks very good.
    Can't wait to see more ;)
     
  18. TKBIG

    TKBIG Active Member

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    Looking good Jim.
    You really need to post pics of that vac-table you made....talking about accessorized. :lol


    Hollar if you need any help or more supplies. :)
     
  19. Morg

    Morg New Member

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    Looking good Jim. BTW, you got mail.
    jon/shunned
     
  20. Goldenrod

    Goldenrod Sr Member

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    nice job Jim.
    So how ya like that KAW chest?
    I got mine along with another fg helmet from James. The chest is nice but to big for me. But would work for bigger clones:)
    I'm glad its over with...well atleast for us. I wonder if scott will ever see his refund.
    -michael
     
  21. GundamZeppelin

    GundamZeppelin Sr Member

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    Its looking better everytime i check in.
     
  22. troopermaster

    troopermaster Well-Known Member

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    Good effort Rodann :thumbsup

    Reminds me of when I first started on my sculpts way back :) I made seperate body casts and sculpt over them with air drying clay,and boy did that stuff crack up on me big time. I did it the hard way (but cheap :p) but got there in the end.I didn't have a vac table to form over the sculpts to make plaster moulds,so I used this remeltable rubber and was great at the time.

    Keep up the good work :)

    -Paul.
     
  23. Rodann

    Rodann Sr Member

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    <div class='quotetop'>(Goldenrod @ May 30 2006, 02:02 PM) [snapback]1253162[/snapback]</div>
    I like it, but yeah, it's big. I KNEW his whole "one size fits all/ready to wear" thing was a bit off. Imagine the whole suit like that? Geez, pain city. Stuff would be better for a mannequin. I don't think the rigid plastic he's using now is much better, either. You need help resizing the chest? It can be done, but you'd have to use a saw and some of the fiberglass resin from Walmart.

    Or resell it to recoup some of your money.;)

    I painted mine up already. When I sculpt my own chest, I'm definitely going smaller. Or less wide. And those chest cutouts should be more rectangular than his.
     
  24. Rodann

    Rodann Sr Member

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    Here are new pics of my plaster shin molds. And the test pulls. They fit better than expected. I'll be adding some material to them, so they overlap some more.

    [image]http://images.andale.com/f2/115/106/2379504/1149368375767_Clone_Armor_Molds_001.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1148994479067_Clone_Molds_Testfit_003.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1150821619428_Clone_Molds_test_pulls_001.jpg[/image]

    And here's my vac table, Stace.;) I added a place to hold the heat gun so it won't burn my countertop, and there are two hold-downs for my frames. Gives me hands-free molding, so I can hit the vac button without losing the seal.:)

    Yes, that's an "ove' glove". :lol

    [image]http://images.andale.com/f2/115/106/2379504/1147096263998_Clone_Armor_Vac_Table_002.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1147931436803_Clone_Armor_Vac_Table_004.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1149912952456_Clone_Armor_Vac_Table_003.jpg[/image]

    And here's the fg chest, Goldenrod, with an improved Bly stripe. Pre-weathering. The other was temporary, anyway. I made the gaps in the stripe, by rubbing candle wax on the spots, then scratching off the paint after it dried.

    [image]http://images.andale.com/f2/115/106/2379504/1149521035570_Clone_Armor_chests_002.jpg[/image]

    [EDIT]: Moved my pics vertically- I hate having to scroll sideways.
     
  25. TK9120

    TK9120 Sr Member

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    Jim, do you know any of the details of the KAW armor? I thought is was supposed to be scanned from a LF maquette. If it is why is it so big? Did he have a "one size fits all" or is that how big they are supposed to be? The helmet is huge as well.

    BTW, nice work on the molds. :thumbsup

    Vin
     
  26. OdiWan72

    OdiWan72 Master Member RPF PREMIUM MEMBER

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    Hey Jim, PM´d you reg. the large chest armor you posted.

    Markus
     
  27. Rodann

    Rodann Sr Member

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    Vin, the KAW helmet will sit on a normal person's shoulders (without armor even bulking you up) , and STILL be hard to see out, so I have no idea where he got his dims. The chest is too wide to comfortably put your arms at your side, and I've been told the forearm is too big, but the elbow is too narrow to fit ON. No idea what's going on there. After three years, I'm tired of waiting for this deadbeat to send completed armor to ANY of the 15-20 people on the list. I got the chest pieces as a settlement, and I'm officially out of the project. So it cost me $1000 for a helmet that was delivered in August, and now finally these two chest TEST PULLS.

    Which is why I decided to say screw it, and sculpt my own armor.
     
  28. TK9120

    TK9120 Sr Member

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    I'm tired of waiting too. I haven't waited as long as some others though. I'm debating on taking some other pieces plus my helmet and being done with it. If starts getting these done and the reviews are good, I might wait a little longer.
     
  29. Reactor drone

    Reactor drone Well-Known Member

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    <div class='quotetop'>(TK9120 @ Jun 1 2006, 01:18 AM) [snapback]1253942[/snapback]</div>

    If he was working from the CG/maquette sizes it won't fit any living person.The waist on the CG troopers is too narrow and they cheated on the movement(the armour miraculously merges when troopers move).

    All real life clone armour has to be a compromise to fit on real people and still move.
     
  30. Rodann

    Rodann Sr Member

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    <div class='quotetop'>(Reactor drone @ Jun 3 2006, 04:26 AM) [snapback]1255320[/snapback]</div>
    Exactly.

    I wore the chest to Concarolina this weekend, and one new thing we all agreed on: It's not only too wide, but it's also too SHORT. It should come down more for an average person's chest. So I know what I need to do when I sculpt my own.......forget this one exists. :lol

    James used the LFL images too literally, not taking into account the fact that there were so many compromises done in the CG. One thing I just realized......we've seen his pieces (i.e. "TEST PULLS") in several pics, but never TOGETHER- never being WORN. I wonder if that was intentional. Did he even TRY to wear them himself? Or did I miss that melodrama?

    His armor would have made a great mannequin, in the sense that it would have LOOKED good and accurate standing still, but I have to say it's really not meant to be worn. Just the chest piece by itself this weekend, combined with my formerly comfortable styrene armor, was very uncomfortable. The size and shape was way off, and I'm "only" 5'9", and 205 pounds. I'm really glad I got out. Just wish I had a refund for the remaining pieces. :unsure

    This would be a near impossibility, but I'd love to see a side-by-side comparison of his armor, and Clonesix's. I mean, two guys WEARING them. I bet it would look like a caricature of Clone Six armor.


    Anyway, I'm going the affordable route. And once I get mine done, I'm pulling a set of untrimmed pieces for Baron Fel and Polymerarmory to pour plaster in themselves, to make/resculpt their own armor.

    Gotta recruit more Clones. :D
     
  31. Rodann

    Rodann Sr Member

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    Hey, guess what- SURPRISE. My plaster thigh molds cracked as bad as the clay shins. :lol

    Lesson to all other stupid people: Do not cheat by filling plaster molds with wood. :p I was running out of plaster, had all 4 thigh pieces halfway poured, didn't feel like making another trip out to Lowe's (in the same day.), so I started building them up with wood inside the plaster. That, it turns out, is a "No no". :D

    Doesn't really matter, though. I'm going to cut each hunk of plaster in half, elongate them, add more material to the middle, then add a layer of material to sculpt a more accurate profile from. These first molds were only meant to be something to work off of, kinda like using a Kelloggs ep2 helmet as a base for an ep3.;) The original maker of my old thighs had no "eye for detail", so instead of making them curved and then pointed in the front, he made them barrel-shaped, and just added a flat ridged layer to the front. Not even close. And don't even get me started on the backs of them. I've heat-formed them TWICE, but it's time to just give up and start over.
     
  32. Rodann

    Rodann Sr Member

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    I finally got time to do some more work.

    I fixed the molds. Tore them apart, reassembled them with plaster putty, and resculpted them yet again. :D Kinda like a puzzle, when the cracked apart. :lol And I think I found a cure for cancer in all the mold I discovered. :p Hooray for Lysol. :eek:

    The front thighs are closer to completion, while I've only just started on the back thighs. I took my solid plaster "slugs", and started sculpting new details on them, beginning with making them larger and adding the rear "scallop". I still haven't gone back and redone the shins (first page), because I wanted to get these started curing.

    I can't wait to have an UPGRADE from the crap I've been wearing all this time. :D


    [image]http://images.andale.com/f2/115/106/2379504/1151408085912_Clonetrooper_Armor_Thigh_Molds_001.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1148008950499_Clonetrooper_Armor_Thighs_0011.jpg[/image]
     
  33. Rodann

    Rodann Sr Member

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    Update 8-7-06

    I've finally had time and energy to finish what I started. Or is it finish starting what I started?

    I cleaned up my shin, calf, and knee molds, and I'm VERY happy with what came out of the oven.


    For my custom Mando. I sold my 1960's Alpine motocross boots, so I needed something. And I got to use my old Clone "shoe covers". Hey, Dengar can have TK shins, right? ;)
    [image]http://images.andale.com/f2/115/106/2379504/1154011978286_Legs_003.jpg[/image][image]http://images.andale.com/f2/115/106/2379504/1154022305602_Legs_002.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1156839412801_Legs_001.jpg[/image]


    My Bly shins and knees, too:
    [image]http://images.andale.com/f2/115/106/2379504/1156537398451_Legs_005.jpg[/image][image]http://images.andale.com/f2/115/106/2379504/1155082274310_Legs_004.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1153525802615_Legs_006.jpg[/image][image]http://images.andale.com/f2/115/106/2379504/1155986663487_Legs_008.jpg[/image]
    http://images.andale.com/f2/115/106/237950...89_Legs_007.jpg
    http://images.andale.com/f2/115/106/237950...4_Legs_0010.jpg

    Details:
    [image]http://images.andale.com/f2/115/106/2379504/1157005111120_Legs_0012.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1153769767610_Legs_0015.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1154123117310_Legs_0014.jpg[/image]


    Molds and stuff:
    [image]http://images.andale.com/f2/115/106/2379504/1156210202248_Clonetrooper_molds_001.jpg[/image]
    [image]http://images.andale.com/f2/115/106/2379504/1154230140217_Clonetrooper_molds_002.jpg[/image]
    http://images.andale.com/f2/115/106/237950...r_molds_006.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_007.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_003.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_004.jpg
    http://images.andale.com/f2/115/106/237950...s_knees_002.jpg
    http://images.andale.com/f2/115/106/237950...r_molds_005.jpg
    http://images.andale.com/f2/115/106/237950...s_knees_001.jpg

    I pulled a few sets of each, and made another knee mold so I can pull two at once. Just makes more sense than wearing out the one mold.

    I've started these 6 pieces first, as an "upgrade kit". Because for years now, I've had (ahem) "inferior" shins. ;)
     
  34. TK9120

    TK9120 Sr Member

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    Nice work Jim. I see you've been busy. Keep it up. :thumbsup
     
  35. fettster

    fettster Sr Member

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    they look really nice.

    looks like your off to a good start
     

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