Re: Pep to Molded Plastics War Machine,Gatling Gun,Stronger Mount and Other WM Weapon
So I wanted to post some progress on my War Machine Helmet, with faceplate mechanism! This is only a test fit. Nothing is permanently attached to the helmet as it needs tweeking and ultimately paint. Even the eyes are only taped into place without the lenses for effect.
I am using TheRealStarks stunning faceplate mechanism and the beautiful MaskedRider War Machine Helmet!
Please read this disclaimer before you go on!
Disclaimer. Everything I am posting here was done/ is being done with the full awareness and very helpful cooperation of Ryan aka TheRealStark and Leslee aka MaskedRider. If you have any questions at all, please ask me immediately and I will answer as quickly as possible.
Ryan has done his usual outstanding job of creating a Hardware/Software interface that is ideal for our Iron Man/ War Machine builds.
I received mine in the mail and closely watched Ryans very clear instruction video. I bench tested the assembled mechanism of of the helmet and it is wonderful!!
Ryan has done a great job of generalizing and creating a mechanism that should work in multiple different helmet applications if the measurements are the same as the ones Ryan lists in his thread.
That makes it a perfect basic(you will have to modify several parts) fit for Leslee's War Machine helmet! The key measurement is the width of the "Widows Peak" in the center of the helmet.
Here is the mechanism installed!
Please be aware as well that, in this particular instance, this IS NOT a plug and play assembly! Ryan has put a ton of work into making this as fool proof as possible but that said, here is some information concerning the install into my MaskedRider helmet.
Leslee made the helmet very strong and it is solid as heck, made out of fiberglass. The inner part of the widows peak is curved and angled, so a plate of Syntra was cut to the exact outline of the servo plate and actually sanded to an angle (like a door stop). This will act as a shim to level out the servoplate and bring it into a more appropriate position.
You can see in this picture I hacked out some of the area next to the widows peak to accept the lift armatures... This is not completed as I am deciding just how much of a lip to leave around the edges. I think 1/4 inch will work nicely to act as a catch and work to keep the faceplate from sagging in when it is closed.
The tape you see is to allow me to use hot glue for a test fit. I did not want to put hot glue on the helmet or parts that need to be mounted as the hot glue can be a bear to get off!!
I intend to mount the servo plate with recessed in Chicago screws to allow for removal/repairs ect.
Please be aware that I have over 30 years experience building custom R/C Airplanes as I tell you about these next steps.. I am not at all a master builder, but alot of the airplanes I built needed pretty heavy mods to fit all the equipment/servos/retracts/flaps ect. Soooo, I have experience...of a sort LOL!
The angle of the armatures was too angled for my taste. It would have required a rather thick shim between the rotating center section between the armatures and the faceplate to make contact. This adds weight as well to the faceplate, an issue I will talk about later.. Ryan mentions this shim in his tutorial... I did not want to do this, so I used my heat gun to change the angle of the armatures.

wacko
Disclaimer 2. I do not suggest this or recommend it. I did it at full risk, knowing that I could damage it or render the 3D printed parts useless!!
When heating I went slow! The armatures are made from plastic designed for 3D printing. As such it is light and hard, yet it goes soft suddenly and stays soft again until it has cooled. I was able to take a large part of the angle out. If you want to explore this more please ask or if enough War Machine guys are interested I will take pictures and explore a how to. You can see in the above picture it worked great.
Stay away from the ends, only work the center of the arm and for the love of all that is holy, Do not keep it assembeld as you try heating things up. This material will weld itself together and destroy your parts!
The only thing I had to fix after doing this was to re drill the lightening holes on the armatures using my drill press, as the center holes in the arms went a little oval. No harm no foul right.
Next I attached my faceplate. As I have said the MaskedRider helmet is made out of fiberglass. It is heavy. The servo is rated at 38 oz of torque.....

that is not the same as a dead lift of the heavy face plate. :sick
After some trials, I too managed to burn out my booster board #1

$
I talked to Ryan and ordered another on line, a simple resolder, and I was back in business!:love
Wrong, I had taken the faceplate off for this retest. I bench tested it again and.....pause for effect.... it burned that booster board out as well :sick ....
I did some brainstorming and determined that I had burned out the super heavy duty metal geared servo during my initial Heavy Face Plate test, so that shorted out the new board.
Poor Ryan LOL! after bugging Ryan again, and again *sigh* and again, (he was so helpful and great through the trouble shooting) I decided to do a direct wire to a six volt NIMH R/C battery pack I had lying about. I ended up with this LOL!


opcorn
I know it looks a jumbled, mess, but that is my doing. Ryans looks much more stream lined, as will mine when I rewire and put new switches in. As I chose to use an R/C pack, I no longer have the recharge mode on the booster, but a slow charger is like 6 $ I had several lying about, so no cost for me.. It would probably be better to have Ryan talk you through this wiring, but suffice to say it works like a charm now!
Now on too the next issue....

opcorn:eek
I could not risk using the heavy faceplate again and had to think of a good solution.

cheers:cheers:cheers:cheers

)
The MaskedRider facelplate is flawless, but heavy. I wrote to Leslee and he basicallytold me was very sorry to hear that I was having issues due to the weight of the faceplate (this not his fault at all, he builds a superior quality helmet) and Leslee explained that he was limited to the materials that he has available in the Philippines....basically fiberglass.
I tried to sand the inside of the faceplate down to thin it out, but quickly realized that I would likely destroy this faceplate before it was ever light enough to not threaten the electronic package.
Back to my disclaimer. I asked Leslee if he was ok if I were to make A (1) single copy of his faceplate to cast in plastic and epoximite. This combo is literally 1/3 the total weight of the original.. Honestly Leslees helmet might be the real War Machine helmet!! It is strong!
He said "yes that it was ok with him". I was very honored at his permission and even more honored that he has noticed my War Machine build and said to me that he "likes the direction I am taking it in!!!"
I want everyone to be clear on this.
I am making only what I need to solve this situation with Master Leslees' permission. I will not under any conditions make more. The mold has already been destroyed and I will not entertain even one request for a copy. I hate recasters with a passion and think they are the lowest of the low to steal anothers hard work.
For those who are in the same boat as I was, Master Leslee is a very gracious and helpful person. If you need his advice or help please talk to or PM him. Do not take the permission he granted me as blanket permission to recast his awesome work.
That said, here is a video of the helmet and mechanism in action!!


opcorn:thumbsup
Sorry about the skinny video. Here is the link!
https://www.youtube.com/watch?feature=player_embedded&v=58BeX47B55s#t=2s
The wires will be shortend and they only go to that small orange 6v battery pack. All parts, wires and batteries will be placed in the helmet as this is designed to be a self contained set up!!!
M