Thorssoli's Ironman MkIII Build - Finished Suit Pics Page 26!!

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

Any possibility that you can upload the STL files for the hand?

No I cannot. They're not mine to upload. As I mentioned in the first post, I can't share anything about the files.

Last night when I was posting pics, I forgot to add this one:


That's the look so far. I need to make the legs again and scale them a bit bigger.

 

[pRoJectEarth7]

Re: Just What This Forum Needs: Another Ironman Build

This is too much AWESOMENESS :eek... blows my mind...

Keep building... cheers!thumbsup

 

[jballard86]

Re: Just What This Forum Needs: Another Ironman Build

thats disappointing but understandable. Maybe one day that will change, it all looks awesome though.

 

[Zendragon]

Re: Just What This Forum Needs: Another Ironman Build

no offense to many others, but THIS is an IM build thread. I almost passed it up till I saw thorssoli's name on it.

Can't wait to see how this one turns out!!

 

[Camaro91]

Re: Just What This Forum Needs: Another Ironman Build

I go away for a few days and come back to all these progress photos, it's looking phenomenal so far!!

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

I've been running the gamut of problems with the CNC machine. Yesterday I tried to carve the first half of the abdominal section and a Z-axis calibration issue kept it from carving deep enough. It's not a huge problem, I'll just have to re-calibrate and run the same piece through the machine again.

Today I was trying to carve the second half of the ab section and the breaker Lopez was plugged into tripped. So now he's carving the second half of the second half and in the morning he'll re-carve all of the first half.

On the plus side, I now have me a jaw:


On the down side, I apparently had a typo when I set the scale of the chin and it doesn't quite line up with the faceplate. So now Jarvis is working on a new one with the correct scale.

Stay tuned...

 

[captain avenger]

Re: Just What This Forum Needs: Another Ironman Build

Subscribed!

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

New chin is printed:


The magic number was 92.1% of the size of the last one. Here's a closer shot:


Here's the side showing how well the new piece mates up with the faceshield:


These are the (nearly finished) slices of the abdomen section.


I already picked a few of the parts off of the one piece. The other piece still needs a few more inches of cutting. Unfortunately, the flexshaft on my CNC machine finally decided to eat itself this evening:


I'll replace the flexshaft in the morning. This tends to happen from time to time, so I keep a spare on hand. I'm pretty sure it's because I'm running the machine for quite a few more continuous hours than it was ever intended for.

In the meantime, I'm slicing up the next few parts in order to feed them to Lopez. I've got the upper arm parts laid out already. Next I need to slice up the 3d models for the forearms. By the end of the week I'll have prototypes for everything from the hips up.

It's almost too easy.

 

[FakeBritishAccent]

Re: Just What This Forum Needs: Another Ironman Build

Keep it rollin', Shawn! Like many others, I tend to avoid IM threads because there's just so damned many of them...but once I saw it was YOUR IM thread, I was in. All of your posts here (as well as your posts in "My Brain is Leaking...") are super fun reads.

Good luck with the build, dude! Don't let the haters get you down.

-Jonaas

 

[zodiac]

Re: Just What This Forum Needs: Another Ironman Build

Looking awesome! This is probably the most interesting thing to happen in Petaluma in years.

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

Thanks again for the compliments.

Progress continues. Last night I had Jarvis print out the bottom part of the helmet that will be removable when I mold and cast the pieces:


Right now he's working on the top right quadrant of the helmet:


One of these days I'm going to have to take a time-lapse video of the printing in progress.

For now, in order to speed up the print process, I'm making the main portion of the helmet in eight pieces. This way it cuts down on the amount of time the machine will spend moving in the z-axis (the slowest movement it has) and since the resolution is so fine, the resultant seams will be virtually invisible by the time I join the slices back together.

Unfortunately, the seams left behind by the slices of the CNC machine will take more work. On that subject, here's the re-carved set of parts for the abdomen:


I should have the waist assembled tomorrow. While I'm doing that, Jarvis will be making the top left quadrant of the helmet and Lopez will start on the arms.

Stay tuned...

 

[Peejfro]

Re: Just What This Forum Needs: Another Ironman Build

cant wait to see fruition on this you are a legend man, i like it alot!!!!!!!!!!!!!!!!!!!!

 

[Jippin]

Re: Just What This Forum Needs: Another Ironman Build

It's looking ruddy amazing.

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

Thank you again for the compliments. I can't tell you how flattering it is to read the "I wasn't going to look until I realized it was your Ironman build" posts. Hopefully I won't disappoint.

Today I attached a couple more pieces to the pelvis section:


I also assembled the waist section:


Unable to resist the urge, I went ahead and stacked the pieces up on couple of one-gallon buckets:


The raised area on the front of the waist section is actually a separate piece. Without putting it in place, the belly is exceptionally flat:


Since the inside has the extra thickness of MDF, I can't overlap the pieces the way they will be once they're copied in (much thinner) fiberglass. Once I've started pulling copies, this whole assembly won't be nearly as tall.

The details on the back are interesting:


The series of spinal segments are separate pieces that I'll be carving out soon.

In the meantime, I've started coating the MDF pieces with epoxy in order to harden the surface in preparation for smoothing. Here's the chest parts:


And the waist parts:


In other news, the top half of the helmet is printed:


The faceplate fits properly:


Now that I'm getting the hang of how to manipulate the models and feed them to Jarvis, I'm really starting to like this machine. The bottom right quarter of the helmet is in progress right now. It's a 17-hour build. One more like it and I'll have the whole helmet together. Then all I'll have to do is a tiny bit of cleanup (something like a 600-grit wet sanding) and the helmet parts will be ready to mold.

Stay tuned...

 

[Peejfro]

Re: Just What This Forum Needs: Another Ironman Build

awesome!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

Lopez has been acting up, so I haven't made any progress on the arm parts I'd laid out for cutting yet. Annoying as that is, I'm pleased to report that Jarvis is still going strong. Here's the latest thing he's given me to show off:


It's going to be tight, but I'm still confident it'll fit:


I'd try it on, but there's some edges inside that I need to leave in place until I've got the bottom left quadrant attached in order to make sure everything is aligned properly:


That last section of the helmet will be done in about three hours or so. For now, at least now I know the jaw will work:


Tomorrow I'm goint to tear Lopez apart and figure out what the problem is. That machine is okay when it's running properly, but the failures happen often enough to make it a nuisance most of the time.

Stay tuned...

EDIT: I should also mention that I started on some of the smoothing and filling to get rid of the unwanted seams in the torso parts. I should have some pictures tomorrow.

 

[blickfangQ2]

Are you going to make a run on this someday ?

Nicely done!

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

Are you going to make a run

Probably. I'll have to see how the final piece came out first. Then the master will need a bit more cleanup. Once that's done I'll have to mold it up in four separate parts (main portion, rear section, faceplate, and jaw) so it might be a while.

 

[Qui-Gonzalez]

Re: Just What This Forum Needs: Another Ironman Build

What will this nifty new toy mean for your RC build? (subtle hint wink wink)

 

[Peejfro]

Re: Just What This Forum Needs: Another Ironman Build

wow that is so cool man