Noob TK bucket casting question

[Timmythekid]

Having just received my first TK bucket to build, I was a bit startled when I unpacked the kit. What was sold as a 2mm ABS bucket is remarkably thin, at least along the edges, certainly not 2mm thick. While I can't squish any major parts of the pieces, I'm wondering if this is normal for a vaccuum casting, or is cause for alarm. Any thoughts?

 

[Amish Trooper]

Post some pics. What is the make of the kit?

 

[pandatrooper]

Its pretty common as most of the edges are formed at the base of the buck / mold. So as the plastic gets heated and stretched, it gets thinnest at these points.

Armor makers can use thicker plastic but it would mean softer details being captured.

 

[Robert412]

I believe your solution is right here:

http://www.therpf.com/f24/heavy-duty-helmet-sandtrooper-105361/

you're welcome.

 

[Timmythekid]

Yeah, Robert, I've already posted a question in that thread in regards to possible casting alternatives. Definetly the route I'll be going once the assembly is done.
As far as the build, after lurking here for months and months, I'm almost afraid to say what it is, as the purchase was made before I'd found out about all the tortured, divisive arguing over what constitutes a non-recast lid. I will say that what I've since discovered is that it's a lid which is likely TE derived, that despite the hystrionics of all the arguments about recasting this particular piece, it's pretty well regarded at FISD, and that looking at the thing you'd probably say "hey, someone VACCUUM formed THIS!"...
(so shoot me, I had not found the RPF yet and so was totally unaware of the controversy around pieces of this..."lineage" shall we say, and the thing looked pretty good for my budget and intentions)

Thanks, guys - just really didn't know what to expect as my only experience so far with any helmets have been DP CA and DP Regular Vinyl helmets seem to be a HELL of alot thicker!

 

[LizardJedi]

Thanks, guys - just really didn't know what to expect as my only experience so far with any helmets have been DP CA and DP Regular Vinyl helmets seem to be a HELL of alot thicker!

Thicker, but less strong.

2mm is referring to the thickness of the plastic before forming. Kinda like a quarter-pounder-with-cheese, its 1/4 patty before its cooked, afterwards its lighter. After forming it, the plastic stretched, especially in complex areas (which the edges would be).

If you really wanted to, you could glue some reinforcement pieces of ABS to the inside, or coat it with resin (or fiberglass it). But chances are, its fine. Especially since you'll be putting edging around the edge anyway.

 

[Amish Trooper]

Simple reinforcing trick is just some ca glue and a cotton tshirt cut strips or squares to size and mix with the glue and apply to the areas you want to reinforce.

 

[Timmythekid]

...Kinda like a quarter-pounder-with-cheese, its 1/4 patty before its cooked, afterwards its lighter...QUOTE]

Well, jeeze, now I'm just hungry...
Thanks for the crash-course, LJ! That's what I was thinking I was seeing, and particularly about the starting plastic gauge vs final product, but had a moment of worry about what I had here when the wife picked it up and gave me a withering look about what I'd brought home. And as far as vinyl vs abs? No kidding! My CA Vader scuffs and nicks if you breath on it wrong. Still the pride of my collection so far, and plan on fixing the neck and giving it a nice paint job someday, but it does have its problems. Thanks also for the tips, guys (about the T-Shirt trick - I think I saw something similar on a thread about converting a stunt to a hero ANH lid, but didn't really get what was being done. Thanks for clarifying that, Amish Trooper!).