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

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

Today I finished the jacket mold for the last piece of the helmet:


Which is good, because I've got to start casting that piece so I can catch up:


I'm calling the abdomen section 99% done:


The rest of the waist is not far behind:


Same goes for the diaper:


It still needs some attention, but it's getting there:


In other news, I got Lopez up and running again, so he's carving out the last pieces of the re-scaled chest as I type.

Stay tuned...

 

[ROBOSTEVE 0671]

Re: Just What This Forum Needs: Another Ironman Build

Again, Awesome work! love this thread! :thumbsup

 

[animefan]

Re: Just What This Forum Needs: Another Ironman Build

I think youve started the new trend of iron man bonnets lol
p.s enjoying your progress pics

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

Ironman bonnets? Sure.


That's most of the first casting with the edges trimmed and taped together. I think it fits pretty well. Here I am holding the faceplate in place:


Here's the whole thing sitting on a post:


I'd post pics of it next to the prototype, but the thin shell of the printed original didn't survive mold removal:


Since I neglected to post pics of it finished, here's the mold for the back piece of the helmet:


Lopez didn't really make progress last night. I've fixed the y-axis problem I was having, only to find a z-axis problem. There was a dirty sensor that was causing inconsistencies in the carving. It's fixed now, but this is all he was able to get done in the meantime:


That was supposed to be the right side of the upper chest. After I cleaned the sensor, the second attempt came out much better, but I didn't snap a picture. I'll get that tomorrow.

 

[The Ronin]

Re: Just What This Forum Needs: Another Ironman Build

I'd post pics of it next to the prototype, but the thin shell of the printed original didn't survive mold removal:

Seeing destroyed masters always makes me sad, but then again you can't make an omelette without breaking the eggs. Keep up the awesomeness.

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

I know what you mean. At the same time, I've also had plenty of them come out fine but still end up useless because they're made of things that are too heavy or breakable to use as a prop for carrying around. So as often as not they'll be tucked in a corner for a while until I get sick of looking at them. I do wonder what they think of me at the local dump when I'll occasionally empty the trash bin and a bright pink assault rifle will pop out.

In other news, the last carve for chest parts seems to have come out pretty well:


It's also worth mentioning that about half of the pictures I post can be seen in much higher resolution on Flickr if you click on them. You know, if that's what does it for you...

 

[Crank729]

Re: Just What This Forum Needs: Another Ironman Build

Looking completely awesome as usual. Also, your work has made me want to turn all of my future mold masters pink.

 

[quovadis0920]

Re: Just What This Forum Needs: Another Ironman Build

Every time I see an update it makes me smile. Yey! Another one to make my day. :thumbsup

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

...your work has made me want to turn all of my future mold masters pink.

Trendsetter. That's me. Rustoleum "Berry Pink." That's the Thorssoli Standard Prototype color.

Every time I see an update it makes me smile. Yey! Another one to make my day. :thumbsup

This should be right up your alley then...

yesterday I assembled the re-sized chest and tried it on:


Much better than the original attempt:


I also assembled the left thigh. Here are the parts the as I left them when I shut down for the night:


Today I started filling in the seams on the new chest:


While I was doing that, Lopez carved out the back of the neck:


Here they are assembled:


And fitted in place after I'd sprayed the chest with gray primer:


Then it was back to filling seams:


About this same time, the primer had dried on the new chest, so I did some sanding and put on a coat of red primer:


I did the same thing on the smaller parts of the chest:


In order to speed up the process, I've rejected the notion of coating the surface to reinforce the MDF before filling and finishing. It'll go faster, but it will require several coats of primer before the MDF stops soaking it in and I can get a decent finish on the surface.

 

[brand]

Re: Just What This Forum Needs: Another Ironman Build

wow it's impressive I wish I had some your toys

 

[ROBOSTEVE 0671]

Re: Just What This Forum Needs: Another Ironman Build

Loving these updates with pictures ! brilliant mate, Such a great inspiration as well to see how you've tackled all this with the milling process in wood and then the smaller parts to be 3d printed, It's all stunning work! So glad I stumbled across this thread, thanks again for sharing your working processes :thumbsup

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

So Jarvis has gone and made me some re-sized flaps for the new, smaller torso:


I've also gone ahead and knocked out most of the fairing on the seams and whatnot:


Hopefully I'll have it all shiny and pink in a couple of days.

Right now Jarvis is working on the largest of the three shoulder parts. If all goes according to plan, it's supposed to be a 44-hour job to make that part. The reason it will take so long is because the vertical axis moves very slowly and there's no way to orient that part to avoid making it tall.

Lopez carved out the complete spine last night and right now I've got him working on a new, resized shin. So I'll have lots of things to work on tomorrow.

In case you missed it, I'm offering helmets in the Junkyard.

 

[Philly]

Re: Just What This Forum Needs: Another Ironman Build

How long did the chest parts take? I'm gearing up to CNC a full suit much like yours as a solid display for my sons bedroom. I wish my CNC had a material feed option, it takes ages resetting for each part

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

The chest was four separate carves of about 12 hours each.

The biggest annoyance I have when Lopez is working properly is the fact that he only has one speed. Carving is just af slow cutting foam as it is cutting ironbark.

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

After 44 hours of build time, Jarvis has made the first shoulder part:


Here it is with the support material cleaned off and held in place:


And from the other side:


Right now Jarvis is working on the inner shoulder plates and Lopez is carving out some new shin parts.

Stay tuned.

 

[Bigturc]

Re: Just What This Forum Needs: Another Ironman Build

Shawn-
I was wondering what was up with your shoulder parts .. then I realized it's all support material!!! Wow .. I'm pretty sure you wouldn't have done it that way if material wasn't free! lol :thumbsup

As for the rest, with the Object30, I'm sure you already know this, but try to print the parts so that the top/exposed surface of the suit doesn't have support material touching it! It's gonna have a finish that is gonna be night and day vs the one touching the surface material! Less work for you afterward!

I learned the hard way myself!

Keep at it!

 

[Peejfro]

Re: Just What This Forum Needs: Another Ironman Build

???????????? i am constantly in awe of your work brother, amazing!

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

...then I realized it's all support material!!! Wow .. I'm pretty sure you wouldn't have done it that way if material wasn't free! lol :thumbsup

I've only got a limited amount of material as part of the prize package. It's basically what was calculated to be a typical amount consumed in six months' usage. I'm a little over halfway through it already.

In this case, there's not all that much support material here. And given the significant convex shape, the only way to avoid this much support material would be to break it up into several smaller parts. Then I'd have to spend extra time cleaning up seams. I also tried a whole series of different orientations, but it turns out that the automatic placement function works well for picking the most economical layout.

I did the same thing with the inner parts of the shoulders:


So here's the three big pieces of the shoulder:


And here's the whole stack:


Fortunately, the shoulder pieces all look to be symmetrical, so I can use one mold to make the pieces for the right and left sides.

Lopez is almost done with the new, re-sized shin. Right now Jarvis is making all of the little nuts and bolts for the chest, shoulders, and elbows. Tomorrow I'll be doing the final fine-tuning on the arm parts.

I should be making at least one or two molds in the coming week. Stay tuned...

 

[ROBOSTEVE 0671]

Re: Just What This Forum Needs: Another Ironman Build

Great work Shawn! those turned out ultra clean, quick question for ya, are you going to add tabs in there so the two parts of the shoulder have a pivot point behind the shoulder bolt? Really looking forward to seeing how you handle this, Great build, love seeing the updates.

 

[thorssoli]

Re: Just What This Forum Needs: Another Ironman Build

I hadn't really thought about making them pivot functionally, but looking at the clearances between the parts, there's no reason I can't. The only issue will be working out a stop or strap of some sort to limit their travel so the parts don't just flop around.

Not much of an update this morning. I did a bit of work on the spine parts yesterday:


Jarvis spat out all of the pivots and bolts for the upper body:


Today I've got a lot of bodywork to do filling seams and smoothing out parts. The arm, waist, and pelvis pieces are very close to being done. The chest needs a bit more work, and the right shin is out of the machine and ready to assemble.

Meanwhile, I'll get Lopez started on the elbows and the knees.