Re: Just What This Forum Needs: Another Ironman Build
Thanks for the comments guys. Sorry about that last post. It was a long and hard day and at the end I was looking at all of the pics and thought, "I'm really too tired to explain all of these..."
So here's the shots I didn't post:
First up, the finished boot prototype:
And the toe:
And the neck:
Here's Trevor laying up the mothermold for one of the thighs:
These are the boot parts blocked up for molding:
I started by building up thickness under the undercuts:
Same for the collar:
Here's the hip pod boxed for molding:
Here's the bigger flaps for the back:
Using the same basic design for open-faced mold, I set up all sorts of small pieces and started pouring rubber. Lots of it:
I also laid up a 3-part fiberglass mothermold for each of the shins:
I printed out kenlandrum's new and improved unibeam model:
It fits okay, but I need to re-print the center piece:
Still a few other molds to make. I'm not sure why, but I keep neglecting to mold the inner shin pieces:
The last thing I did before leaving the workshop was to set Lopez the Robot Whittler to work carving out the little plates that go in the hip joint.
The next morning (yesterday) I pulled the hip plate parts out of Lopez, assembled, prepped, and painted them in my standard prototype color:
Then I started pulling apart all of the molds I'd made the day before:
I spent a few minutes fooling around with some of the pieces:
Then it was time to start rotocasting and pulling copies:
After the tiniest bit of prep work on the belt sander and flapwheel grinder, I was able to do some test fitting:

The parts are a bit snug, but that's probably got something to do with the fact that I rotocast them a bit on the thick side and I was wearing heavy coveralls instead of my spandex tights.
Meanwhile, Lopez carved out the butt plates:
Which prompted more screwing around:
Here they are assembled:
I primed them last night, but they'll still need a bit more smoothing and shaping before they're ready for molding.
While that's going on, I've got a lot more parts to prep before I can get started on painting them:
I also need to overhaul the workshop and get set up for finish work:
Fortunately, these two pieces are all but ready for primer:
Much to do in the next couple of days. Stay tuned...