Aured
New Member
Hello all and greetings from the UK. I'm new here and judging from the quality of many builds I've seen on here this is the place to go for epic costumes!
Anyhow, I'm going to attempt to make a full costume of Clone Pilot Warthog, starting with the helmet.
I'm going to post a brief list of the steps I'm going to build it in, and it would be really great of you guys to point out any errors or tips. Thanks!
1 - Make model in Pepakura.
2 - Print onto cardboard. Glue model together.
3 - Harden model with fiberglass, etc.
4 - Apply Bondo one area at a time. Sand and sculpt until smooth.
5 - Cry deeply as model fails to look anything resembling good.
6 - Keep sanding.
7 - Other parts will be made with, perhaps wood or plasti-card to ensure that the parts are as accurate and sharp-looking as possible.
8 - The final product sanded and with wood/plasticard extras glued or puttied on should be perfect. (I hope.)
9 - Pour plaster OUTSIDE the helmet to make a negative vacuum mold. (I wonder how well the details will stand out in the mold? Will quality be lost?) Saw mold in half and remove model.
10 - Using negative/female vacuum-forming at a high level of pressure (70psi max, as I have heard this produces outstanding quality), form a product out of 1/8 inch plastic. (I wonder if this is possible, as the plastic is so thick? Will it even go into the details?)
11 - Sand/putty to remove seam-lines.
12 - Paint and make inside of helmet.
And the voila! Main concerns are sculpting (making the corners sharp etc.) but I'm sure this can be done with the right tools and improvisation. I've heard sanding is the longest job of all, and I'm mostly concerned about getting the smoothest dome, etc. The rest looks to be a piece of cake judging from builds on here.
Thanks to all who look and reply!
Anyhow, I'm going to attempt to make a full costume of Clone Pilot Warthog, starting with the helmet.
I'm going to post a brief list of the steps I'm going to build it in, and it would be really great of you guys to point out any errors or tips. Thanks!
1 - Make model in Pepakura.
2 - Print onto cardboard. Glue model together.
3 - Harden model with fiberglass, etc.
4 - Apply Bondo one area at a time. Sand and sculpt until smooth.
5 - Cry deeply as model fails to look anything resembling good.
6 - Keep sanding.
7 - Other parts will be made with, perhaps wood or plasti-card to ensure that the parts are as accurate and sharp-looking as possible.
8 - The final product sanded and with wood/plasticard extras glued or puttied on should be perfect. (I hope.)
9 - Pour plaster OUTSIDE the helmet to make a negative vacuum mold. (I wonder how well the details will stand out in the mold? Will quality be lost?) Saw mold in half and remove model.
10 - Using negative/female vacuum-forming at a high level of pressure (70psi max, as I have heard this produces outstanding quality), form a product out of 1/8 inch plastic. (I wonder if this is possible, as the plastic is so thick? Will it even go into the details?)
11 - Sand/putty to remove seam-lines.
12 - Paint and make inside of helmet.
And the voila! Main concerns are sculpting (making the corners sharp etc.) but I'm sure this can be done with the right tools and improvisation. I've heard sanding is the longest job of all, and I'm mostly concerned about getting the smoothest dome, etc. The rest looks to be a piece of cake judging from builds on here.
Thanks to all who look and reply!
