Second Sister from Jedi: Fallen Order

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

thorssoli

Sr Member
RPF PREMIUM MEMBER
This is a FANTASTIC thread. I've always been curious about casting, because I just couldn't get my head around the process. This has laid it out for me and let me know two things: One, I should never, ever try to do this. Two, I should never , ever try to do this. Your work (at every stage) is outstanding! Thank you for sharing it.

It's not as hard as it might look. What I'm doing here is making matrix molds, solid casts and rotocast parts. This is about as complicated as this stuff gets. The easier versions involve just making block molds. Technically much easier to achieve. If you'd like to know more, I actually wrote a book with a pretty detailed section on molding and casting. You can get it on Amazon here: Make: Props and Costume Armor: Create Realistic Science Fiction & Fantasy Weapons, Armor, and Accessories: Thorsson, Shawn: 9781680450064: Amazon.com: Books
 

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

TheForgeProps

New Member
Your 2nd sister helmet looks great- I've been thinking about making one myself, because I absolutely love her design! I'm working on her lightsaber at the moment, because it's also an amazing design (the whole game is full of brilliant pieces!)
 

Dtrasler

Sr Member
It's not as hard as it might look. What I'm doing here is making matrix molds, solid casts and rotocast parts. This is about as complicated as this stuff gets. The easier versions involve just making block molds. Technically much easier to achieve. If you'd like to know more, I actually wrote a book with a pretty detailed section on molding and casting. You can get it on Amazon here: Make: Props and Costume Armor: Create Realistic Science Fiction & Fantasy Weapons, Armor, and Accessories: Thorsson, Shawn: 9781680450064: Amazon.com: Books
Went to add that book to my wish list - it's already there! Curse my family for not purchasing it sooner! My birthday's in August, so I'll start dropping hints now...
 

thorssoli

Sr Member
RPF PREMIUM MEMBER
So...

Once again I've fallen way behind on keeping up with a build thread. Since I last posted, I've hit up my friend Jesse, aka puzzleboxprops to laser cut some cleaner versions of the acrylic visor insert:
50301106718_c85e70a0b8_c.jpg


Once it was heated and bent and the LEDs were installed, it does a much better job of evenly distributing the light:
50493464567_99b06265cf_c.jpg


The view from inside the helmet is a bit blurry because of the lighting setup, but still very wearable for getting around without bumping into things:
50511457207_423f2eb483_c.jpg


I've also prototyped the shoulders, belt buckle, and rank bars:
50076368241_bd54372484_c.jpg


The bracers were 3D printed and I did a lot of bodyshop work to alter the shape into something a bit more wearable:
50226847258_bac34510f1_c.jpg


They were molded in much the same way as the helmet. Here's a shot one of the shiny lightish red prototypes when I was mounting the mothermold prior to pouring the silicone:
50260746053_9a24c2444e_c.jpg


Here's the molds all prepped and ready for casting:
50267201833_d91d4ca1b6_c.jpg


And here's the first pair cast after trimming and a bit of cleanup:
50317995043_0a54595f1c_c.jpg


The belt buckle and rank bars were cold cast with aluminum powder mixed into the resin. The come out looking pretty unremarkable:
50382839131_ff12b02fc3_c.jpg


But with a bit of buffing, they're perfect:
50382133938_40ce4d917c_c.jpg


That made up a full set of the hard parts for this costume:
50360357438_28dd8d8bfc_c.jpg


They were starting to look kinda right:
50383016002_68a85996fc_c.jpg


Being me, I almost never make just one of anything. So I got to rolling out a few more helmets:
50201148497_ff821816a7_c.jpg


After painting, trimming, and installing magnets, they were given a few coats of satin black paint:
50404874588_5dcba1dfc0_c.jpg


Same for the bracers:
50493308761_42ab38f270_c.jpg


And the shoulders:
50493465612_4a475baaf7_c.jpg


Once the lights were installed, they were really looking good:
50509717023_a886a02201_c.jpg


So here's how she looks right now:
50513888427_22c857197d_c.jpg


I've got a collaborator who's helping me out with the soft parts, so hopefully those will start taking shape soon.

Stay tuned...
 

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

darthjones

Sr Member
This looks so great!!! If ever you are going to sell a 2nd sister helmet let me know. I just need something to paint/ tinker with. But it would display so nicely. Just beautiful beautiful.
 

thorssoli

Sr Member
RPF PREMIUM MEMBER
This looks so great!!! If ever you are going to sell a 2nd sister helmet let me know. I just need something to paint/ tinker with. But it would display so nicely. Just beautiful beautiful.
I've got a thread going in the "Project Runs" section of the classified for all of the hard parts, helmet included.
 

Don't want to see this ad? Sign up for anRPF Premium Membershiptoday. Support the community. Stop the ads.

Top