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  1. Member Since
    Feb 2011
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    136
    Sep 28, 2017, 1:13 AM - Re: Logan's Run wall crystal #26

    It's been a little while since I posted here, but I finally did finish a fourth version. Now I've started a 24" version.

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  2. Member Since
    Feb 2011
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    136
    Sep 28, 2017, 1:18 AM - Re: Logan's Run wall crystal #27

    Before I forget, here's the final shot of the one I just finished. I got frustrated with it for a while because the inner foam was making it hard to sand flat. My solution was to carve into the problematic sides, dig out the foam, and replace it with pieces of wood glued together with white glue, and then sealed inside spackle. These took a good while to dry, but afterwards they let me sand the facets as smooth as I wanted them to be.

    Another thing that slowed down the process was that I had built the model incorrectly. Once the error was pointed out, I fixed it by cutting off the incorrect facets. I later corrected the 3D version as well, before starting the 24" version.

    On the 24" version, I've bought a gallon can of Bondo. I plan to make the cutouts with a thick card stock, glue them together, and then fill them with the bondo.


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    Last edited by epoxinator; Sep 28, 2017 at 1:24 AM.
  3. Member Since
    Feb 2011
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    136
    Oct 10, 2017, 2:11 AM - Re: Logan's Run wall crystal #28

    Work continues on the 24" diameter power crystal. I was only able to find a 23 3/4" wood disk, but was able to find some iron-on edge veneer. 7-8 layers of that brought the disk diameter to just above 24", so I have some play in mounting the crystal facets to the surface. (Though it was a bit hard on the non-stick coating of my iron.) The wood surface is WAY more stable than the styrofoam I used for the 12" version. I've given it a couple of coats of white latex primer, and have been sanding it flat in between coats to remove all the wood grain texture. I need to get another can of the latex. I've assembled these paper forms for the surface.

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  4. Member Since
    Feb 2011
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    136
    Oct 10, 2017, 2:20 AM - Re: Logan's Run wall crystal #29

    I am trying an experiment in duplication. Instead of making more paper forms of each crystal segment, I've put them together as molds. I bought a gallon of Bondo, and when I think the forms are complete I will try my hand at creating the crystal segments out of that. I'm hoping it will be more substantial than the paper, and easier to create more uniform shapes. To strengthen the paper molds I have been coating them with layers of wooden craft spreaders on the outside, held together with clamps as they dry to try to keep the flat surfaces flat. When dry I have been painting them with the rustoleum paint I had for the earlier crystals. When they seem rigid enough, after coating them with wax or petroleum jelly or other non-stick agents, I will try mixing up some of the Bondo and pouring it into the molds. I'm hoping this process will save me a lot of the time I have spent on the paper versions in stiffening them up enough to stay rigid so I can sand them flat. I'm hoping I can either try to make them hollow in the center, or fill them up with paper remnants to minimize the amount of Bondo I will need.



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    Last edited by epoxinator; Oct 10, 2017 at 2:24 AM. Reason: misspellings
  5. Clutch's Avatar
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    Jun 2005
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    Oct 10, 2017, 7:34 AM - Re: Logan's Run wall crystal #30

    Awesome sauce!
  6. Member Since
    Feb 2011
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    136
    Oct 15, 2017, 4:38 AM - Re: Logan's Run wall crystal #31

    Getting the base prepared. The first shows preparation with latex primer, sanded in between layers to fill in the wood grain and the border between the edge of the original plywood and the heat-application wood veneer. I used multiple layers of the veneer to both smooth out the edges and scale up the disk to go beyond 24". In the second shot I have spray painted the base with white primer, which has smoothed out all the brushstrokes, sanding marks and completely hidden the edge of the veneer. Moving on to the facets.

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  7. Member Since
    Feb 2011
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    136
    Oct 15, 2017, 4:47 AM - Re: Logan's Run wall crystal #32

    I bought a gallon can of Bondo to make the crystal facets, and so far it has overall been a success. As a newbie to Bondo I'm finding some of the pitfalls of it's use, for example being better about running something along the corners and edges after the Bondo has been poured in to take out all the bubbles.

    I've also learned not to get textured plastic bowls in which to mix because they can create little sections of non-hardened Bondo. I also didn't realize how much heat the Bondo would put out. This softens the oil-based paint that I used to make the paper watertight, and can tend to make that stick to the hardened Bondo. I have a tub of beeswax furniture polish that is a good release agent, except where the Bondo didn't harden.

    The central pyramid has a hole in it because I wanted to cut away a section that had a lot of non-hardened Bondo. I will fill it in tomorrow when I make more batches. I'm hoping the paper molds will last until I get all the copies I want made. I want to have at least one spare of each element. I think if I want to go ahead and keep making these, it would be best if I make "perfect" versions of each element, and then make a Bondo mold of each. I believe such molds will be able to hold up better than these paper ones will be able to.

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    Last edited by epoxinator; Oct 15, 2017 at 4:55 AM.
  8. Member Since
    Feb 2011
    Messages
    136
    Oct 16, 2017, 1:58 AM - Re: Logan's Run wall crystal #33

    Bondo is awesome, except for the smell. My neighbors knocked on my door asking if I had had an accident or something. Since I already had the smell in my place instead of leisurely creating a piece or two at a time I powered through and created all the rest of the pieces today, plus a couple of spares. Instead of fixing the messed up sections it really took less time to just make new ones. Now I have to spend some time sanding them smooth. The amount of heat generated by the curing Bondo proved quite hard on the Rustoleum paint I used to waterproof the molds. It came out stuck to some of the sections, more as the process went along and the paint became more and more damaged.


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  9. RPF Premium Member sean's Avatar
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    Oct 16, 2017, 5:11 PM - Re: Logan's Run wall crystal #34

    Awesome ! but you really shouldn't be doing bondo inside. the fumes and dust are not good for you. safety first. and we would like to keep our prop people around for a long long time...
  10. Member Since
    Feb 2011
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    136
    Oct 17, 2017, 12:46 AM - Re: Logan's Run wall crystal #35

    I won't do it indoors again, but I was under the fan over the stove turned up full blast.
  11. Wheatbee's Avatar
    Member Since
    Oct 2014
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    Grande Prairie, Alberta
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    Oct 20, 2017, 5:03 PM - Re: Logan's Run wall crystal #36

    Outstanding work! Logan's Run is my sci-fi passion and I think this is just some fantastic effort here.
  12. Member Since
    Feb 2011
    Messages
    136
    Oct 22, 2017, 8:55 PM - Re: Logan's Run wall crystal #37

    Just got back from a week in Vegas for a work conference. The pieces have had 5 days to harden and, hopefully, outgas more chemicals. I sanded all the pieces with 100 grit sandpaper to flatten all the sides up, and then with 180 grit to get a finer surface where called for. I didn't photograph that process because I didn't want to expose my camera to that dust. I also wore a dust mask and eye protection so I wouldn't inhale it, and did all the sanding outside.

    Last night and this morning I used PC.7 epoxy to fill as many bubbles I could find, rebuild hard edges and points where the Bondo didn't fully flow into the molds, and strengthened the insides where the Bondo was too thin. I also built up many of the bottom edges to make a thicker surface for attaching the pieces onto the mounting disk. It takes a lot longer to set up than the Bondo, but that was an advantage because there are so many little issues to fix. A bag of plastic gloves and another of disposable plastic bowls has kept my cleanup to a minimum.


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    Last edited by epoxinator; Oct 23, 2017 at 1:31 PM.
  13. Member Since
    Feb 2011
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    136
    Nov 6, 2017, 1:22 AM - Re: Logan's Run wall crystal #38

    So now I'm learning about Bondo shrinkage. At first I thought I was sanding the elements too harshly, but then I lined them up on the base with the overhead printout and learned that, no, it's not me, they all shrank at the same rate. When I set the pieces inside the paper cutout versions I made I can really see how much smaller they have become. Good thing they sat for a week: I would hate to see what would have happened if I had started using the PC.7 epoxy on them before they shrank to their final size. As it is, I'm just hoping that there won't be any more substantial shrink problems in the future. I don't like the gaps in between the elements, and I don't want to cluster them around the center of the base and leave a bare circle around the outside. My solution is to build a base for each element out of wood pieces glued onto paper cutouts of the base of each element. I'm relatively confident that wood and paper won't shrink. When I have finished with each base I will glue each element to it's corresponding base, and then fill in all the holes with more of the PC.7. Then it will be sand patch sand patch sand. I will need to be careful when sanding, not to sand inside the paper glued to the bottom of each base.


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  14. Member Since
    Feb 2011
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    136
    Nov 9, 2017, 1:25 AM - Re: Logan's Run wall crystal #39

    I finally finished the wooden bases. Here I lined them up on the main base with a crystal element sitting on top of each.

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  15. Member Since
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    Feb 1, 2018, 1:08 AM - Re: Logan's Run wall crystal #40

    Work since Christmas. I sanded all the bondo parts down to correctly fit on the wooden bases. That meant I sanded off all the red paint.

    I sealed the pieces with several coats of water-based varnish I had on hand so that when I painted them the wooden parts wouldn't swell. It also fills in the very many small bubbles in the Bondo. I've been having to do a lot of hole patching and bubble filling using the dark-grey PC7 epoxy filler. This filler seems to be harder than the Bondo. Bondo holds in a lot of air pockets, and as I sand these I break through into new air pockets again and again. Sometimes when I'm sanding I start getting swellings in the surface, where I've sanded the surface so thin over the bubble that it starts to balloon out. So annoying: I have to carve away the entire bubble with an Exacto knife so I can fill it in with the PC7 and then sand it flat again.

    Finally the bulk of sanding is done and I've painted them red again with water-based Rustolium paint. I'm painting and then sanding them over and over with finer grit sandpaper to try to get the faces as flat as possible, and to fill the pesky air bubbles that seem to keep coming through.

    I'm hoping to get all the pieces to a point where I can use spray paint and smooth everything out for a finished piece.


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  16. EasternBloc's Avatar
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    Seeking Sanctuary
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    Feb 5, 2018, 11:12 AM - Re: Logan's Run wall crystal #41

    This looks great; I can't wait to see the finished product! Watch out for the Bondo fumes, though. I try to do that kind of stuff over in cathedral where the cubs don't notice the smell because they're too strung out on muscle.
  17. RPF Premium Member sean's Avatar
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    Feb 5, 2018, 11:40 AM - Re: Logan's Run wall crystal #42

    Looking great ! and huge...keep It up
  18. Member Since
    Feb 2011
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    136
    6 Days Ago  Jun 13, 2018, 8:55 AM - Re: Logan's Run wall crystal #43

    Still at it, but a death in the family has kept me away from the project for a few months.
  19. RPF Premium Member sean's Avatar
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    6 Days Ago  Jun 13, 2018, 4:58 PM - Re: Logan's Run wall crystal #44

    epoxinator said: View Post
    Still at it, but a death in the family has kept me away from the project for a few months.
    Sorry to hear this. My Condolences to you and family.
  20. George's Avatar
    Member Since
    Sep 2014
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    6 Days Ago  Jun 13, 2018, 6:10 PM - Re: Logan's Run wall crystal #45

    I'm sorry for your loss,and wish you and your loved ones strength.
  21. Great_Bizarro's Avatar
    Member Since
    Apr 2002
    From
    Texas
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    5 Days Ago  Jun 14, 2018, 8:46 AM - Re: Logan's Run wall crystal #46

    You could mold this in clear plastic. Vacuum form using a thin plastic in red or clear and paint it, and use your original for the mold. Might need to seal it with something to keep the paint off the plastic 1st.. Nice work.
  22. tictoc's Avatar
    Member Since
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    Seattle, WA
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    16 Hours Ago  Jun 19, 2018, 8:06 AM - Re: Logan's Run wall crystal #47

    Interesting. I have never done something (vacuum form) that big with so many facets. You could make a quick custom sized vacuum machine fairly simply...but I wonder, might be difficult to get it to release from the mold. Someone with more experience could chime on about that.

    You would lose some sharpness but gain a uniformity. It would be light. A plastic form could be lit from behind. You could even use a glossy red hips plastic or similar. Some neat possibilities.




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