rocketeer helmet

Discussion in 'Replica Costumes' started by glyntheelf, Aug 15, 2015.

  1. glyntheelf

    glyntheelf Jr Member

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    so ive started work on a Rocketeer costume. starting with the helmet.

    the helmets being 3d printed
    11815915_10152911789951927_1584412800_n.jpg

    after a very long time ive finely got it all taped together to make sure it all fits nice.
    11844202_10152937967546927_448054414_n.jpg

    i then slush cast the inside with fast cast resin.
    20150815_150542.jpg

    the fast cast fills in any gaps and holes saving a bit of work filling with epoxy resin.
    IMG-20150812-WA0000.jpeg

    i then started to sand it with 60 grit sandpaper, thats should give it a good bed for the filler primer to bite onto.
    20150815_150454.jpg

    and that's where im at so far, i plan on chopping off the fin so i can make a single part as its not that strong as it is. i also plan on making it out of polyurethane in the end. hope you finheads like it and if you guys have a any tips and tricks please let me know.

    next up will be the glove flight controls.
     
  2. Ein

    Ein Sr Member RPF PREMIUM MEMBER

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    That's quite clever! I like it. Never thought to slush cast a 3d print like that just to hold it together. It looks like you didn't get too much leakage, too.

    The fin being a single piece is definitely the right idea.

    Did you make the files you printed?
     
  3. glyntheelf

    glyntheelf Jr Member

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    thanks Ein, no i didn't make the file i had to edit it a little to be able to print it and re-size it. i believe it was this file by davypenno2
    http://www.thingiverse.com/thing:850699
    slush casting works a treat. best to sand the insides to help it bite but other then that its great.
     
    Last edited by a moderator: Nov 9, 2018
  4. glyntheelf

    glyntheelf Jr Member

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    i chopped the fin off today and finished sanding
    20150816_130513.jpg

    i cut just below the 3d printed plastic leaving the resin in tacked, that way it keeps it strong then filled in the gap with car filler.
    20150816_130533.jpg

    iv now can use the fin as a template to make it one piece.
    20150816_130608.jpg

    when i come to fixing the fin to the helmet i will wax the fin first then add the weld lines to the helmet and fin. this way i will be able to remove the fin so it makes it easyer to cast.

    ive also made a slow start on the gloves. still need to cut them down.
    20150816_131002.jpg 20150816_131008.jpg
     
  5. glyntheelf

    glyntheelf Jr Member

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    took all day but my gloves are cut and stitched read for dyeing and the rest of the leather to be added.
    20150816_204539.jpg 20150816_204547.jpg 20150816_204602.jpg 20150816_204607.jpg
     
  6. joberg

    joberg Master Member

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    Subbed...that helmet sure looks great. Eager to see the rest:)
     
  7. glyntheelf

    glyntheelf Jr Member

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    today i finally got to give it a few coats of filler primer. the first coat its just a thin coat. this raises the plastic fibers so that i can sand them off with 120 grit paper as you can see in the first pic. the dark patches are where the fibers are standing up.
    20150818_111321.jpg

    i then gave it i good few coats to help fill in the gaps i then sanded the gaps back to the plastic leaving only the primer in the grooves. then another good coat
    20150818_185804.jpg

    i also made a start on the fin, i traced round the original onto a 5mm polycarbonate sheet
    20150818_185647.jpg
    still needs sanding and shaping but it will be perfect for what i need.
     
  8. JPH

    JPH Sr Member

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    why not make the fin out of aluminum? unnamed-28.jpg
     
  9. glyntheelf

    glyntheelf Jr Member

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    Good idea JPH I just had the polycarbonate knocking around. But I might have a look to see if I have any aluminium. Would definitely be better.
     
  10. glyntheelf

    glyntheelf Jr Member

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    today i used some cellulose stopper to fill in some big lines and pin holes, if you have never used this stuff its great it like a very thick paint that can be sanded withing minutes and isn't as hard to sand as body filler.

    stopper applied
    20150819_170800.jpg
    then sanded off with the gaps gone
    20150819_173716.jpg
     
  11. joberg

    joberg Master Member

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    Looking spiffy:cool
     
  12. glyntheelf

    glyntheelf Jr Member

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    ive been doing some work on the glove controls for the past week
    20150831_214127.jpg 20150831_214144.jpg 20150831_214220.jpg 20150831_214229.jpg

    ive also made a rocket base/booster using a lathe and some high density foam. i will make a mold and make two hollow casts of this
    20150828_165318.jpg
     
  13. glyntheelf

    glyntheelf Jr Member

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    ive done a bit more work on the helmet, almost time to add the weld lines and cast.
    20150903_174223.jpg 20150903_174207.jpg 20150903_174152.jpg 20150903_174142.jpg
     
  14. glyntheelf

    glyntheelf Jr Member

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    hay guys its been a while since i last posted but i have been working on my project. i cast my rocket boosters

    20150914_133123.jpg 20150928_202500.jpg 20150925_122804.jpg 20150928_202512.jpg 20151127_163057.jpg

    i also had to make a silicon *coff* plug for the inside of the boosters

    1444329370350.jpg

    as for the fuel pipes i got some flexable water pipes and screwed some bolts into the end then cut the heads off and screwed then into some pre drilled holes on the booster

    20160320_123015.jpg

    the gray pipe i will be using is 6" soil or drainage pipe.

    the gloves are almost fully complete now, i want to add some straps up the arms to keep the cables in place if i dont have a jacket on but that will be a small addition.

    20160320_122748.jpg 20160320_122726.jpg

    to connect the buttons to the jetpack i have some 3 pin connectors

    20160320_122822.jpg

    these will be great so i dont have to struggle getting out the pack and gloves at the same time.

    ive also bought most the costume now,

    20160307_181129.jpg

    ive also orderd some gaiters to go with some boot.

    this is the jacket i ordered

    http://www.ebay.co.uk/itm/Custom-Ta...460140?hash=item35dd250f2c:g:HuQAAOSwPe1UJALn

    and the breeches

    http://www.ebay.co.uk/itm/111848930239?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT
     
  15. glyntheelf

    glyntheelf Jr Member

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    bother boosters are finished and painted.

    boosters.jpg
     
    JPH likes this.

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