Repair of Vader Chest Armor

[Vaders_Happy]

I have recently bought some chest armor and it appears to have suffered some damage in transit. It is fiberglass construction and (sorry I can't post pictures as have no connection for camera to computer, only a camera mobile) the crack runs a small way up the inside of the armor, from the bottom towards the top. It also runs slightly along the 'edge' of the bottom of the armor.

Could this be fixed? I was wondering about epoxy resin or 'super glue'. Would either of these work? I can't put 'glue' across the whole of the crack as it is not in two peices. I can open up the crack only slightly as do not want to fracture the paint and make it much worse. would a little glue in the crack be ok? I couls also put glue 'across' the crack on the under side (where the crack can be seen) as the over putting of glue would not be seen.

I would very much appreciate your assistance. Bst wishes.

 

[ob1al]

I don't think superglue would be strong enough.

I'd fix it with resin if it were me, then sand the fix flush to hide the repair.

 

[James Kenobi 1138]

If it's fiberglass, I'd repair it with fiberglass.

I tried fiberglassing for the first time last year, it was easier then I expected.

You can buy it at any hardware store or autoparts store. It's called fiberglass resin, and comes in either a liquid or a gel. I used the liquid.

It also comes with a small tube of hardener, like a 2 part epoxy. You mix so much of the fiberglass resin with so much of the hardener and mix. Working time varies, I had about 5-10 minutes.

You mix it in a separate clean cup, and pick up some cheap disposable brushes. I also bought some cheap mixing cups from the dollar store.

They also sell fiberglass fabric. You pre-cut it to the size you need, brush down the fiberglass resin, put the fiberglass fabric flat down overlapping the crack, and brush on more fiberglass resin. Repeat a few times.

You do this on the underside, so there isn't much to do on the top except fill and sand the crack after everything has dried.

Be careful. work outside, it's sloppy so mix small amounts and use like 1/2 inch or 1 inch brushes. Work on a covered table or a workbench. If you spill the cup, it's a dog to clean up.

 

[Vaders_Happy]

If it's fiberglass, I'd repair it with fiberglass.

I tried fiberglassing for the first time last year, it was easier then I expected.

You can buy it at any hardware store or autoparts store. It's called fiberglass resin, and comes in either a liquid or a gel. I used the liquid.

It also comes with a small tube of hardener, like a 2 part epoxy. You mix so much of the fiberglass resin with so much of the hardener and mix. Working time varies, I had about 5-10 minutes.

You mix it in a separate clean cup, and pick up some cheap disposable brushes. I also bought some cheap mixing cups from the dollar store.

They also sell fiberglass fabric. You pre-cut it to the size you need, brush down the fiberglass resin, put the fiberglass fabric flat down overlapping the crack, and brush on more fiberglass resin. Repeat a few times.

You do this on the underside, so there isn't much to do on the top except fill and sand the crack after everything has dried.

Be careful. work outside, it's sloppy so mix small amounts and use like 1/2 inch or 1 inch brushes. Work on a covered table or a workbench. If you spill the cup, it's a dog to clean up.

Many thanks. It is on a Vader chest armor peice. The crack is at the bottom on the inside as described. Do you also think superglue would not be strong enough? I was worried that something thicker, such as epoxy or the fiberglass you suggest would not get far enough into the crack to go much good.

If I used the fabric would I need to do anything with the crack itself, or would 'papering over it' be enough? How far round the crack would I need to go with the fabric? obvoiusly it is right on the edge in one part.

The peice is for a 'bust' at the moment but I had contemplated getting more items for a costume. I would like the repair to be able to stand up to the item being moved / handled etc.

Edit - I am in the UK so any brand names I should look out for would be great. Our hardware stores are not like yours byt the automotive shops 'Should' have what you suggest.

 

[James Kenobi 1138]

If you don't reinforce it on the under side with something, it will probably break again.

You could use a 2 part epoxy with some fiberglass fabric, but fiberglass and fabric is just as easy.

As far as brand names go, I'd just ask at the store what they recommend, it's probably all the same stuff with different labels anyways.

 

[Vaders_Happy]

If you don't reinforce it on the under side with something, it will probably break again.

You could use a 2 part epoxy with some fiberglass fabric, but fiberglass and fabric is just as easy.

As far as brand names go, I'd just ask at the store what they recommend, it's probably all the same stuff with different labels anyways.

Sorry, just to be clear, try and get some epoxy / fiberglass in the crack then place the fabric OVER the crack as you suggested Right?

Also ho much over the crack should I go with the fabric, an inch? More / less?

Finally, how many layers of fabric should I use and should they all go in different directions? I have never done this before so you are really helping me. Thanks!!

 

[James Kenobi 1138]

An inch on both sides should be more then enough, and probably 2-3 layers should also be fine.

All the fiberglass resin and fiberglass fabric are applied on the backside, not the side you see when wearing the armor. If the crack is visible on the front side, you will need a filler (like hobby model filler) to fill the crack smooth to the rest of the armor and sand smooth, and then paint (yay!)

 

[Vaders_Happy]

An inch on both sides should be more then enough, and probably 2-3 layers should also be fine.

All the fiberglass resin and fiberglass fabric are applied on the backside, not the side you see when wearing the armor. If the crack is visible on the front side, you will need a filler (like hobby model filler) to fill the crack smooth to the rest of the armor and sand smooth, and then paint (yay!)

Thanks,
1)Should I try and put fiber galss in the crack (at the rear) by flexing it to open out the crack or just put the fabric over the crack (on the back)?

2) should the layers be one over the other or, off centre (of the last one) or at rightangles, does this make any difference.

3) should I let it dry / harden between each layer or put it all o at once?

I can't tell you what a help this is.

 

[James Kenobi 1138]

Thanks,
1)Should I try and put fiber galss in the crack (at the rear) by flexing it to open out the crack or just put the fabric over the crack (on the back)?

2) should the layers be one over the other or, off centre (of the last one) or at rightangles, does this make any difference.

3) should I let it dry / harden between each layer or put it all o at once?

I can't tell you what a help this is.

1. Just brush the fiberglass over the flat area on the back side, you don't want any to leak through to the front (it's pretty thick as long as you don't go overboard spreading it around).

2. As long as you go brush fiberglass-add fabric- brush fiberglass-add fabric-brush fiberglass-add fabric-brush fiberglass and cover the area, you'll be fine.

3. Since you're only doing a small area, and since it's on the back side, and only like 2-3 layers, I'd just do it all at once. Just pre-cut your fabric before you start to just longer then the crack and 2 inches or so wide.

Believe it or not, you're doing exactly what the person who made the armor did except they started with a fiberglass gel coat (the side you see) and added layers of fiberglass resin and fiberglass material to the proper thickness.

 

[Vaders_Happy]

1. Just brush the fiberglass over the flat area on the back side, you don't want any to leak through to the front (it's pretty thick as long as you don't go overboard spreading it around).

2. As long as you go brush fiberglass-add fabric- brush fiberglass-add fabric-brush fiberglass-add fabric-brush fiberglass and cover the area, you'll be fine.

3. Since you're only doing a small area, and since it's on the back side, and only like 2-3 layers, I'd just do it all at once. Just pre-cut your fabric before you start to just longer then the crack and 2 inches or so wide.

Believe it or not, you're doing exactly what the person who made the armor did except they started with a fiberglass gel coat (the side you see) and added layers of fiberglass resin and fiberglass material to the proper thickness.

Thank you so much! You mentioned that it did not need to dry before adding the next 'coat'. Just for future refference, at what point should you stop, let it dry, and start again?

 

[James Kenobi 1138]

Thank you so much! You mentioned that it did not need to dry before adding the next 'coat'. Just for future refference, at what point should you stop, let it dry, and start again?

I would apply all the coats/layers at once, you should be able to do it all in 10 minutes before the fiberglass gets tacky to the touch.

Most fiberglass cures fully in 24 hours.

 

[Vaders_Happy]

As I think of it - How much do I need to use? I meen as I brush it on how thick / sparing should I be?

 

[James Kenobi 1138]

I would mix like 2 ounces at a time.....and that's probably too much.

You brush on a layer, a little thicker then a piece of paper, add the material, brush on another layer making sure it is soaked thru, and so on.

It's much easier then I'm making it sound, it's like paper mache except you substitute glue and news paper with resin and fabric.

 

[Vaders_Happy]

Thanks again. I will pop down to my local auto parts shop on my next day off and purchase this fiberglass that you speak of. What have you done with fiberglass that led you to aquire this knowledge?

Oh and the armor has some flex in it as it stands, would covering the back all over reduce this and make it stiffer. Its just that thats how I think it got damaged and wanted to reduce this happening again.

 

[James Kenobi 1138]

I added a mount to a Vader faceplate and a Vader dome, plus some reworking to a more ANH look.

Yes, the more fiberglass you add to the back the stronger and more rigid it will become.

 

[Vaders_Happy]

I added a mount to a Vader faceplate and a Vader dome, plus some reworking to a more ANH look.

Yes, the more fiberglass you add to the back the stronger and more rigid it will become.

How would you recomend tackling the whole chest peice then? Should I do this one layer at a time/
Should I do the crack first
How big should the peices of fabric be for adding layers and is there a number I should work to ie minimum or maximum?

 

[Too Much Garlic]

I would work on the crack first and then see if more is needed.

But, be aware that fiberglassing an item adds weight to it, sometimes pretty substantial. Especially in a large piece such as chest armor.

 

[fettster]

where in the uk are you, im in the uk too.

what james kenobi has told you is exactly right however i know of an easier fix for you if you dont want to experiment with fiberglass.

get yourself down halfords and you can buy a car body filler which has fberglass in it, i forget what its called, i use p38 which is the same stuff but without the fiberglass, the one you want is p34 or something like that ( its a black tin with blue writing on it)

all you would do is mix a batch and smear it over the crack, i would tack the crack first with superglue and then add the filler.

if you want to go downthe fiberglass route, you can buy a kit from halfords with all that you need, (fastcast resin, matt, hardener and a mixing bowl and brush)

its polyester resin rather than epoxy but if you havent used it before, i honestly suggest you use the filler for ease after all, its the exactly the same stuff and the resin, just in a paste form.

alternativly if you live near birmingham, you could drop it round and ill stick a layer of mat in for you