Vacuum Forming, Rinzler Cosplay.

Letum

Letum

Member
Hello world!
So I'm a little new to this. Im starting a project. Yes a Rinzler cosplay. Ive been thrilled with the movie ever since my second viewing at the theater. The first time I went to see it I went because Daft Punk made a appearance and they did the soundtrack. Being a HUGE Daft fan I had to go. After seeing it I fell in love with the movie. Of course Ive seen the first one. But never did i imagine that Legacy would be anything like it was.

ANYWAY, Back on topic.

I'm taking on a new challenge and going to try to create a Rinzler costume. But after doing months and years of research I still haven't quite figured it all out. So here I am asking for opinions, thoughts, critique, support, ect!

The first thing that I'm going to work on is the helmet. Ive watched countless videos on vacuum forming. And homemade vacuformers look easy enough. BUT I'm not sure it will do what I need it to do for this helmet.
So I looked into making molds, But again, I have no idea how to both make them or how i would use them!
So what I'm asking for here is help.

Ive been following ArtFunk's helmet thread. The "Rinzler helmet START!!!" Thread to be exact. And I understand everything he has done thus far. But I really like to know what my plans are and how im going to do everything.

SO! Ive been looking into vacuum forming, and I just dont know if I could create an object that large of a scale on a home made vacuformer! Im very lost in thought and I need you guys to help pull me out!
Let me know how you think i should do this! Should i go with vacuforming? Or should I try to learn more about molding and if it will help me at all? Im a little lost. :confused

Thank you ahead of time for your input and time! Ill be checking back frequently for your responses as I am thrilled to be working on this.
 
vaccum forming for the helmet is definatley a good idea. you should probaly try to do it with the clear plastic bought online, then try to tint it. for the costume what im using is craft foam. its cheap but alot of people dont like it because it requires alot of work. now most people would say to try to buy the type of fabric used to make the suits (you know the hexagon pattern?). DONT LOOK FOR IT. you will not find it and if you do it will be very very very expensive! the best idea would be to find a picture of the pattern, cut out the hexagons then use it like a stencil and spray on the hexagons. for the lights, i dont like EL wire just because its very expensive and it looks kinda stringy, if i were you i would either use EL tape or reflective tape which both work very well! anyhow if your gonna do the craft foam, look up how to make craft foam armor, its simple but again requires tons of work and cutting and you might want to try to make another cosplay with it first before you try rinzlers because it is very detailed! heres a picture of what mine looks like with the craft foam if you want to see what it looks like so you'll get a good idea in your head about what you want to do! btw the pink phone is not mine!
securedownload.jpg
[/IMG]
good luck!
 
RINZLERTRON said:
vaccum forming for the helmet is definatley a good idea. you should probaly try to do it with the clear plastic bought online, then try to tint it. for the costume what im using is craft foam. its cheap but alot of people dont like it because it requires alot of work. now most people would say to try to buy the type of fabric used to make the suits (you know the hexagon pattern?). DONT LOOK FOR IT. you will not find it and if you do it will be very very very expensive! the best idea would be to find a picture of the pattern, cut out the hexagons then use it like a stencil and spray on the hexagons. for the lights, i dont like EL wire just because its very expensive and it looks kinda stringy, if i were you i would either use EL tape or reflective tape which both work very well! anyhow if your gonna do the craft foam, look up how to make craft foam armor, its simple but again requires tons of work and cutting and you might want to try to make another cosplay with it first before you try rinzlers because it is very detailed! heres a picture of what mine looks like with the craft foam if you want to see what it looks like so you'll get a good idea in your head about what you want to do! btw the pink phone is not mine!
securedownload.jpg
[/IMG]
good luck!
Click to expand...

Lmao, Sorry the pink phone threw me off. Its fine.
Anyway. Yeah, for the under armor, Ive already got plans for the hex pattern. I made a hex pattern in my favorite program called GIMP, and im sending off a full turtle neck leotard to be printed with the hexagon shapes. (Seeing as how my stepmom's dad own a tshirt printing factory. XP)

Also yes, The EL tape is what I will be using for the lit parts. I'd like to see what your armor will look like when its done. ALSO. The vacuforming, What I'm a little worried about is if I make a full helmet in a vacuform is it possible that the plastic will rip and tear or not mold properly due to such a large size?

Funny thing is, I work at a factory that produces gladware, and other tupper ware products. We make the plastic ourselves. I have loads of it at home. Sizes ranging from 5x12 feet to sheets no bigger than a peice of paper. And in all kinds of colors.

And Finally, Ive checked out your DA page and your bioshock helm is awesome. Im a rather large fan myself.

Anyway. So yes, those are my concerns. Any help to clear those up?
 
Letum said:
Lmao, Sorry the pink phone threw me off. Its fine.
Anyway. Yeah, for the under armor, Ive already got plans for the hex pattern. I made a hex pattern in my favorite program called GIMP, and im sending off a full turtle neck leotard to be printed with the hexagon shapes. (Seeing as how my stepmom's dad own a tshirt printing factory. XP)

Also yes, The EL tape is what I will be using for the lit parts. I'd like to see what your armor will look like when its done. ALSO. The vacuforming, What I'm a little worried about is if I make a full helmet in a vacuform is it possible that the plastic will rip and tear or not mold properly due to such a large size?

Funny thing is, I work at a factory that produces gladware, and other tupper ware products. We make the plastic ourselves. I have loads of it at home. Sizes ranging from 5x12 feet to sheets no bigger than a peice of paper. And in all kinds of colors.

And Finally, Ive checked out your DA page and your bioshock helm is awesome. Im a rather large fan myself.

Anyway. So yes, those are my concerns. Any help to clear those up?
Click to expand...
yep i should be able to clear it up! vaccum form it, then fiberglass the inside! just dont fiberglass a small portion of the front because you do want to be able to see out! im very new at all this also so ya its taking me a long time.... its been two weeks and im still adding details that i forgot to the rinzler suit. the only concern i had about mine was that rinzler i know had the hex pattern... but i dont remember ever seeing it so i wasnt sure if i should put it on there or not. anyway yes thank you, ya the delta helmet was one of the first things i had ever made on my own :)
 
RINZLERTRON said:
yep i should be able to clear it up! vaccum form it, then fiberglass the inside! just dont fiberglass a small portion of the front because you do want to be able to see out! im very new at all this also so ya its taking me a long time.... its been two weeks and im still adding details that i forgot to the rinzler suit. the only concern i had about mine was that rinzler i know had the hex pattern... but i dont remember ever seeing it so i wasnt sure if i should put it on there or not. anyway yes thank you, ya the delta helmet was one of the first things i had ever made on my own :)
Click to expand...

Do you think that a homemade vacuum former would do the trick?
Also, I was thinking about after I got all the little details worked out with my master helmet, that when i decided to form it if i put it on like say a rod, so that i could just cut off the bottom and still have an slightly enclosed helmet. Im trying to find an example....

AH! ^^ Like this.
helmet71.jpg


Make sense? Sorry if im being confusing.
Let me know if i need to clarify anything.
 
Tried to follow...you are asking about making the Rinzler helmet from a homade vacuformer?

Definatly can be done, but the issue with the shape of the helmet is that it has a sorta wrapped-to-the-side portion which will act like an undercut when you form it. Now, I am looking at the screen used helmet now..there is a seam line along the sides of it. I can see you can make the main portion out of PETG plastic and then make the bottom section independantly from either ABS or molded fiberglass/slush cast resin.

Just make sure you build your former oven properly! I built one awhile back and the thing worked, but the oven was slightly uneven for heating..
 
tubachris85x said:
Tried to follow...you are asking about making the Rinzler helmet from a homade vacuformer?

Definatly can be done, but the issue with the shape of the helmet is that it has a sorta wrapped-to-the-side portion which will act like an undercut when you form it. Now, I am looking at the screen used helmet now..there is a seam line along the sides of it. I can see you can make the main portion out of PETG plastic and then make the bottom section independantly from either ABS or molded fiberglass/slush cast resin.

Just make sure you build your former oven properly! I built one awhile back and the thing worked, but the oven was slightly uneven for heating..
Click to expand...

Hey there,
I was kind of thinking of it this way.
What if I made sort of a stand like a base for it to stand on. Sort of like this
cap_holder_small.jpg
except with a base instead of a wall connector. That way it will form underneath the helmet too and i can just cut off the excess?

Or if you dont think that will work how would i bind the two parts together?
 
Letum said:
Hey there,
I was kind of thinking of it this way.
What if I made sort of a stand like a base for it to stand on. Sort of like this
cap_holder_small.jpg
except with a base instead of a wall connector. That way it will form underneath the helmet too and i can just cut off the excess?



Or if you dont think that will work how would i bind the two parts together?
Click to expand...
good idea, accept i would try to make the bar shorter. im gonna make mine where its more of a thicker bar and shorter but im gonna make it where some of the bottom is visible so i can atleast cover the bottom part.
 
RINZLERTRON said:
good idea, accept i would try to make the bar shorter. im gonna make mine where its more of a thicker bar and shorter but im gonna make it where some of the bottom is visible so i can atleast cover the bottom part.
Click to expand...


Thats exactly what i mean! ^^
I was just trying to give an idea lol.
 
Letum said:
Hey there,
I was kind of thinking of it this way.
What if I made sort of a stand like a base for it to stand on. Sort of like this
cap_holder_small.jpg
except with a base instead of a wall connector. That way it will form underneath the helmet too and i can just cut off the excess?

Or if you dont think that will work how would i bind the two parts together?
Click to expand...

I see what you are saying, but I don't think it'll work too well. The reason is because of the function of the former won't really work in that fashion. The closer your mold to the platen, the better it will form.

The idea of putting a standing pole on the base will raise it too high. On top of that, the plastic can only stretch so far, and getting that far under the sculpt will more than likely not happen with out it ripping or cooling long before it could get that far under
 
RINZLERTRON said:
tubachris is right, if you make it too tall its gonna rip. but depending on how tall it is it shoudnt hurt it. like say its only about 3 inches up, it shouldnt hurt
Click to expand...

I mean, you sculpt the basic shape, what you can do is add a an inch and a half or so of MDF as a "riser" on the very bottom, it'll just be tall enough to give you a significant amount of excess to cut from, with a more defined edge to use as a cutting guide. That's probably your best option instead of trying to get plastic to completly form around the buck
 
tubachris85x said:
I mean, you sculpt the basic shape, what you can do is add a an inch and a half or so of MDF as a "riser" on the very bottom, it'll just be tall enough to give you a significant amount of excess to cut from, with a more defined edge to use as a cutting guide. That's probably your best option instead of trying to get plastic to completly form around the buck
Click to expand...
yeah yeah thats what im talking about :love!
 
I had a chance to hold a filmed original biker helmet. :eek The main body was a left and a right with a seam down the middle.:love The top visor and face plate a single pull. But... the plastic was about 40 thousands thick! :eek Hope this help!

thermal
 
As someone who does this essentially for a living, the best advice I can give you is:

Don't re-invent the wheel. Learn from people that have experience.

Don't assume that equipment will solve your problem. Equipment just presents new challenges. How you learn with the new equipment is the solution... not whether you can build the equipment or not.

Hollywood has more resources that you. They probably injection molded what you're trying to vacuum form. Prepare yourself for compromises.

Optically clear PETG is a beast... and nobody is talking. I've been asking but the resources seem to be silent. Experience will fill the gap, but thats counting lots of trial and error.

I think that you're on the right path, but nobody else has gone there yet. If you need help from an experienced vacuum former, ask for it, Don't assume that you'll figure it out quickly. There are reasons it takes time to master something. Focus on the project, not the technique.

I'd be glad to help, but can't lead the charge myself.. much like many other members. Crowdsource the project and share the results.
 
Sean Bradley said:
.

Optically clear PETG is a beast... and nobody is talking. I've been asking but the resources seem to be silent. Experience will fill the gap, but thats counting lots of trial and error.
Click to expand...

What do you mean by "optically clear PETG"? lol the PETG I've worked with has been clear enough for my crappy eyes to see through :lol
 
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