Thorssoli's T-60 Power Armor Build from Fallout 4

[thorssoli]

Any new stuff? How are the sanding girls doin'? :lol

There's been a shortage of sanding girls. I really need more of them.

There has been new stuff. Though the last couple of months have been a bit cramped with WonderCon and Silicon Valley Comic Con, I have made tiny bits of progress.

First off, I glassed the little shoulder bits into the big shoulder bits:


Then I used some Bondo Glass to add pegs to align the back and chest to one another:







Then we spent some quality time goofing around with the armor:


And I finally permanently attached the lugs to the lower back:


Those were fiberglassed into place from the inside and became the effective backer plate for the screws that hold the footman loops that the shoulder straps get attached to on the bottom end. I also glassed in a plywood inner back plate:


Then I added some ALICE pack shoulder straps:


Then there was a bit more screwing around:




The next day, since I was alone in the shop, I locked myself in the noisy dust making room and cut out all of the necessary cutouts on the bottom of the chest box:


The lower chest plate was slid into a matching curve cut into the bottom of the chest. Then I gooped it in place with a generous helping of Bondo Glass:


Here it is from the front:


Then I blobbed on more Bondo Glass to make sockets on the back of the chest that will accept the pins sticking out of the front of the back:


So far so good:


At this point, there were a ton of parts just sitting around in primer, so it was time to start adding silver basecoats:






Here's my friend Freddy admiring some of the shiny:


And Noelle adding in more silly:


Still the last few bits to mold, but progress continues:


We're almost there.

 

[McCarthy83]

Cracking work as always.... looks awesome so far....

 

[CAKComedyProps]

Awesome!

 

[thorssoli]

So this is my friend Rachel pouring the mold for a few more resin details:


The parts themselves were cold cast in aluminum. I'm pretty happy with the results:


After gluing those onto either side of the chest box, I decided to add a few bullet dings to the front. I started by drilling holes in the fiberglass part and taping over the holes from the inside:


Then I applied some Bondo to the holes and used the end of a pen to sculpt it into about the right shape:


Once that had cured, I did some quick sanding and touch-ups:


That done, the whole thing was given a coat of primer and then sprayed with it's base silver color:


The only other bit of progress was the installation of the recessed bolt details on the shins:


Now I just need to install the tanks, mold and cast the rubber parts, rig the hands, build stilts into the feet, weather everything, and put it all on.

Piece of cake.

 

[Uridium]

OMG OMG... I cant wait to see this finished....

 

[joberg]

Oh dude:eek Amazing:cool!!!!!!

 

[thorssoli]

Today I started sculpting the rubber bits for the knees and elbows. The first step was having my assistant Chuck trace out the elbow opening:


Then I rolled out some clay and made up a corrugation pattern that looks about right to me:


Next I'll pour a stone mold and slipcast a couple of copies in latex or neoprene. More on that later.

In the meantime, my friend Danielle has been making progress on the minigun parts:


They'll be ready to mold soon:


Soon...

 

[Sluis Van Shipyards]

Make sure to tell people that that is a modded minigun because the original is really weak. :lol

 

[joberg]

Wow, unbelievable :eek Maybe the Mods could create a "Behemoth Costume Thread" for you man:cool!!

 

[SofaKing01]

You Sir, and all your helpers, are insane! I say that with the utmostest of respect!

BRAVO! Can I hang out with you?

 

[thorssoli]

Make sure to tell people that that is a modded minigun because the original is really weak. :lol

I'm going to be happy if it just turns out to look the part. People can say whatever they want about it after that.

Wow, unbelievable :eek Maybe the Mods could create a "Behemoth Costume Thread" for you man:cool!!

This is the little one. My other ongoing project is the big one:


Back on topic, the rubber sculpts for the joints were finally molded. Here they are (along with a piece for the big guy) all ready for pouring:


Then filled with Ultracal 30:


The next day, it was time to flip each of them over, remove the clay sculpt, and be ready to pour some rubber:


Here's my friend Freddy pouring the rubber into one of the molds:


Once they've been filled, drained, and dried three times, they'll be ready to peel and we'll have the rubber bits to go inside the knees and elbows.

Otherwise, most of the progress lately has been little cosmetic things like adding the "roll bars" to the front of the ankles:


And a bit of progress rigging the shins and feet to the stilts:


I'm suddenly on a deadline for this project, so expect a lot of progress in the next few days.

 

[joberg]

Another "Wow Day" at Thorrsolieek

 

[thorssoli]

I'm way past due for an update. There's been a lot of progress, but here's a highlight until I can sort through all of the photos and make sense of it all:

 

[joberg]

Great vid! And yes, it's HUUUGE:cool Great final effect for sure!

 

[Sluis Van Shipyards]

That came out great!!! Do you guys have anything showing how you did the rust on the other suit? It looked really good.

 

[zapwizard]

I saw the video on Tested. It looks amazing. I love the paint job.

 

[thorssoli]

Great vid! And yes, it's HUUUGE:cool Great final effect for sure!

It'll look better with the upper arms and hands re-rigged. But I'm definitely happy with the scale of it.

That came out great!!! Do you guys have anything showing how you did the rust on the other suit? It looked really good.

This guy?

That one's mine. Freddy did his in the blue and white, but I wanted mine to look like something from in the game. I think I achieved it.

I'll explain the rust soon.

I saw the video on Tested. It looks amazing. I love the paint job.

The blue one? It's okay. That was Freddy's doing. I'm still looking forward to doing the Atom Cats paintjob.

So here's the latest update on this project...

The rubber parts for the joints came out alright. Here's an elbow being de-molded:

And this is a knee hanging to dry a bit more:

Here you can see me installing an elbow piece:

It fit pretty well:

Most importantly, it covered my skinny little nerd arms:

While still allowing for plenty of flexibility and motion:

Freddy concentrated on rigging the foot parts onto the stilts:

Then bolting the shins onto the front of the stilts:

Here's an early test of the functionality with all of the lower leg parts in place:

Here's Freddy's suspender arrangement for the big rubber "thunderwear":

When I got around to rigging mine, I bent a piece of 1"x1/8" aluminum flat stock around the inside of the top edge to give me something stronger for the rubber to be riveted onto. Then I suspended the thigh armor from that strip using a piece of 1" nylon webbing. Here's how my rig looked:

For painting, all of the parts were given a base coat of Dupli-Color Chrome, then heavily blackwashed to tone the shine down:

This was mostly handled by my friend Vinny:

He did pretty good:

The next day, my friend Madison started the rust washes:

These were just rust-looking acrylic paints in colors like burnt sienna, raw umber, red oxide, and so on that were dribbled onto the surface without thinning, then slathered all over the part using a wet foam brush before being dabbed off with rag that was soaked in watered-down paint and rubbing alcohol. The effect was pretty convincing for surface rust:

At some point Vinny took over the rust washes:

He did pretty good:

For the areas meant to look like heavier, scaly rust, the wet paint was dusted with cinnamon. That's what gets me this look:

Meanwhile, Freddy took his own set of parts from my molds and painted them in his shop. That was this one:

I still like my raw steel rusted look better:

I still need to rig the hands so they can move and rearrange the knee joints so they'll stay aligned when I'm walking around, but that didn't stop me from strapping on the whole suit out at the abandoned Mare Island Naval Shipyard in Vallejo, CA for a rushed photoshoot:

There's still a few other ergonomic issues to work out:

But preliminary cellphone snapshots look okay:

And we had a lot of fun doing it:

So there's that.

 

[Utri]

The thunderwear looks like a dwarf suit!

Fantastic, been loving watching this build, as always.

 

[joberg]

Aced it once again! :thumbsup

 

[Sluis Van Shipyards]

A wash and cinnamon?! That's it?!? I was expecting some crazy super secret formula I hadn't heard of before! :lol That looks really good!