Thorssoli's First Order Builds - Captain Phasma FINISHED on Page 21!

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Alright, I'm way overdue for an update.

For starters, I pulled the flametrooper prototypes out of the molds:


I've got most of the armor molds put together at this point, but let's focus on the chest piece. Once the prototype was removed, I cleaned up the mold, polished it, coated it with release agent, and laid up the first copy:






I got a little carried away with the fiberglass, so it's a tiny bit heavier than I'd like. This always happens with the first round of pulls from a new set of molds. It was a sticky, smelly day:


Once the parts were cured, I was pretty excited about pulling them and doing the rough trimming. Here's the first pull of the chest plate:






One minor challenge will be sorting out which of these plates goes on the backs of the thighs and which pair goes on the sides of the ribcage:

I'm sure they'll make more sense later.

At this point, I still need to mold the backplate, shins, one of the ankles, the upper arm parts, and the shoulders. Fortunately, they're all polished up and ready to go. Here's the backplate:


Here's the upper arm plates and the 2nd set of ankle plates:


Speaking of shiny prototypes, I've finally tuned up the thermal detonator prototype for Phasma:


I've also printed a bigger set of phasma phingers:


So that's almost coming to an end.

More soon. Stay tuned...

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Maked some toe molds for the Phasma armor:



I started by stuffing a pair of boots with as much newspaper as I could cram into the toes. Then I vacformed a sheet of styrene over them and laid up the mold on the styrene.

After I pulled the mold off, I went ahead and sculpted the tarsal guards:


These were the last two armor plates I had to prototype. The sculpt was a bit lumpy, but I was in a rush so I went ahead and molded them anyway:


One of these days I'll remember to snap a picture of the parts that came out of the molds.

On the subject of Phasma/trooper armor, I've also finally gotten around to molding the Thermal Detonator. Here's the beginning of pouring the silicone mold:


The mold itself was a pretty simple block mold with a jeweler's cut up the side that will be glued to the back of the armor. The end cap was molded separately:


In the end, the molds worked out just fine and the parts came out great:


I rotocast the main body to keep them lightweight. Once the open end is trimmed, the stem of the cap will be able to fit inside. I suppose I'll be able to keep my car keys in there or something.

Finally, on the Phasma front, I've found a few minutes to make the rubber gasket pieces. I started by working out the dimensions and cutting an outline out of scrap sheet stock:


With the outlines set, I glued on lengths of dowel to make all of the ribs:


Once I'd built up the rows of dowel, I smoothed them over and built up the edges with oil-based clay:


At this point they'd become a lot thicker than I wanted, so I mounted them to a piece of plywood, built a cardboard drip wall around them, and poured a border of casting resin around them:


This effectively raised up the outer edge of the sculpt, so when I poured the silicone molds, the parts would end up being thinner. Here's all of the rubber poured:


The next morning I pulled the molds:


My first set of test castings were made with Smooth-On's Flex Foam It 17 mixed with a bit of black pigment and backed with spandex fabric:


The end result was a bit stiffer than I would have liked. Next I'll be trying a softer urethane rubber and possibly re-molding a set in order to pull them in black neoprene.

More on that later.

Meanwhile, I've continued to tinker with the flametrooper armor. A couple of weeks ago I pulled the first copy of the backplate:


It still needs proper trimming, but I think it'll work:


I couldn't resist the urge to try it on and snap a selfie:


So now I have mold for all of the Flametrooper armor plates except for the shins. There's no good reason why I haven't gotten to them yet.

I did go ahead and carve out the bracket that holds the fuel tanks onto the backpack. Next I'll figure out an inexpensive way to make the tanks (I'm reluctant to mold and cast a big tube) and then thing will get really interesting.

That'll be about the same time as I finally finish prepping a handful of TIE Pilots too:


So that's a thing.

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Finally painting up a handful of these beauties:


Just a bit more polishing and I'll be happy with the gloss:






In other news, I've made shin molds for the flametrooper. Sadly, I only got photos of step one:




Today I'll be pulling the first pair of shin parts, trimming them, and doing a quick duct-tape fit test to strap everything on.

Hopefully I'll remember to snap pics.

Stay tuned...

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

SHalamar said:

Pleeease tell me it'll be available as a kit. I've been looking for Flametrooper armor for some time.
(I promise I'll try not to look too ridiculous in it.. I'm rather tall.)

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Shoot me a PM. I'm ready now.

Instvogel said:

Looking awesome!
Please let me know when you're done with the kit! I am 6'6 and I really want one!!!!!

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I now have all of the molds for the complete set of armor parts. Next I'll focus on the fuel tanks and pack. Shoot me a PM if you'd like to discuss the armor parts for now.

Here's a pic of my friend Jason strapped into the full set:


He's only 5'10" and has really thick thighs, but it worked out. The parts were only rough-trimmed, so the edges aren't quite right. Here's the back:


Flamethower next:

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

I love it! Looks fantastic!

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

pnag said:

I love it! Looks fantastic!

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Thank you for the kind words. I was starting to wonder if anyone was reading this thread anymore.

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

We are definitely still following, your work is amazing.

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

I just got your book from Amazon so I definitely watch the thread as well!

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Yes, great in-progress pics.

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

mmhnc said:

We are definitely still following, your work is amazing.

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karmajay said:

I just got your book from Amazon so I definitely watch the thread as well!

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Spyhunter2k said:

Yes, great in-progress pics.

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Thanks, guys. Positive comments do a lot to help fuel these projects.

I've been a bit distracted by my other projects lately, but I've finally molded the last two bits of the Phasma armor. Now I can cast the "nipple clamp" greeblies for the chest armor and the little KitKat blocks on the left calf:


In other news, I've finally painted up a Phasma helmet to keep for me:

Um... and a few spares?

So now that all of the molds are (finally) done, it's time to clean them, prep them, and lay up a complete set of smooth armor that I can shine up, chrome, and weather until it looks the part. I also need to assemble the cut out parts of the bracket for the flametrooper's fuel tank pack:


...And clean up the 3D printed bits:


I just need to stop being distracted by all of the other cool things:




Always a challenge.

Stay tuned and please feel free to let me know that I'm doing it all wrong.

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Everything looks great! I really like the paint job of the Phasma helmets. Fallout and Rogue One, huh? :thumbsup /end_fuel

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Did you use the same wood router to make the Fallout helmet? Nice!

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Bogleo said:

Everything looks great! I really like the paint job of the Phasma helmets. Fallout and Rogue One, huh? :thumbsup /end_fuel

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Fallout, Rogue One, Ironman 2, Halo, Warhammer 40K, and more. It's a non-stop flood of awesome in my shop lately.

Sluis Van Shipyards said:

Did you use the same wood router to make the Fallout helmet? Nice!

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That one was entirely 3D printed. This next one, this is carved on the Carvewright with some 3D printed details added:


Back on topic...

Progress. It's happening:










I've got ID numbers to add to a couple other helmets today and then it's time for the final clearcoat.

I also painted some red buttons:



Shiny armor pics coming soon...

And I'm helping a friend with her stick:


So that's a thing.

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

So, I'd finished my flame trooper helmet about a month ago, and saw Thorssoli's request for pics - I'd meant to upload this ages ago, but as my Phasma was nearly finished, I thought I'd wait til both were done. Anyway, this is my ft helmet...



And my Phasma was about to get it's final sealing coat after the two step chrome paint job - well, until my 4 year old daughter knocked it down the stairs...



It's in about 30 pieces. I've rebuilt from some smashed up things before, but this is beyond hope. I'm heartbroken

EDIT - I should stress, they were concrete steps!

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

pnag said:

View attachment 685677

It's in about 30 pieces. I've rebuilt from some smashed up things before, but this is beyond hope. I'm heartbroken

EDIT - I should stress, they were concrete steps!

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That's horrible. I've still got the molds if you'd like to get another one. They're pretty sturdy, but I suppose there's only so many times they can bounce on the concrete.

On the TIE pilot front, progress continues. I've got all of my shoulders all ready for primer:


Today I'll be finished sanding the chests and backs:


I'm also almost done prepping the chest boxes:




Belt boxes too:


Then it's just a big pile of gauntlets and a couple of helmets to clean up:


Paint soon. Soon...

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

And a new Phasma bucket has been ordered - thanks Shawn!

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

pnag said:

thanks Shawn!

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I aim to please.

On that front, I've been focused on TIE armor again for a minute. For now, I've fitted tee nuts to the back of all of the chest and belt boxes, then drilled holes so I can mount them to the chest armor:


Then I cleaned up a few more sets of chest boxes:


And primed them:


Now I just need to finish prepping all of the switches and buttons:


Stay tuned for the shiny stage...

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

your a machine, thorssoli. Amazing work!

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Boy you must love sanding

Re: Thorssoli's Episode VII Builds (Flametrooper Progress Continues on P12)

Thats crazy work