Bengrim's Darth Vader reveal project

Bengrim09 · Oct 31, 2016

Update !! :lol
Ive been very busy at work so I've not had to much time to do anything on my reveal, but today was a very quiet day so I've had a little play I've had a go at making these don't know what you would call them if you know please tell me :thumbsup

I made one from aluminium at first but just not happy with it, I think the material was a little thick

and the loop over the top was a bit to short, I made another and tried to shave the thickness down but that went by by.
so I resorted back to my 1.2mm steel and cut / filed / bent a fresh piece and added the backing plate as you see in the picture below and I've also made the loop over a little longer

As you can see the backing plate has another little plate underneath it and has bent/curved edges as you can see on the pic with the green arrows pointing them out

Going to give it a coat of primer shortly pic to follow and if it looks ok then I will make another tomorrow

Bengrim09 · Oct 31, 2016

With primer
l like it !
l like it a lot!!

Bengrim09 · Nov 7, 2016

My dear wife found me a piece of fabric for the inside of my mask yesterday, can't seem to find the correct material anywhere been to boot sales, charity shops heck I've even asked my very old and I mean my very old customers ( they keep there old stuff ) if they have any old suits/clothes that migh resemble what I'm looking for, it will have to do for the time being until something closer is found
Anybody got any ideas ?

Original below i have zoomed in more so I can see the pattern it's more a zig zag than a herringbone pattern, but it's not that noticeable with the naked eye.

Just reviewed my post and I can't even tell the pattern of my material sorry for the pic quality

Kroenen77 · Nov 7, 2016

Wow great stuff that you made!
About the fabric:Its a lot darker in real because the pics are made with heavy flashlights.This is a big problem with most of the pics from the revealmask.
Do you have a lasercopy of this part?It should be made of very,very thin sheet.My vovoder is near finish..but without this part I cannot glue it in the mask.

Bengrim09 · Nov 7, 2016

Kroenen77 said:
Wow great stuff that you made!
About the fabric:Its a lot darker in real because the pics are made with heavy flashlights.This is a big problem with most of the pics from the revealmask.
Do you have a lasercopy of this part?It should be made of very,very thin sheet.My vovoder is near finish..but without this part I cannot glue it in the mask.

http://up.picr.de/27367836kw.jpg

hi buddy nice to hear from you again
it's funny you should ask about this part, as I'm in the process of drawing this up and making a mould, as im going to make some from melted aluminium. With work being so busy I'm not finding enough time to get it done as quickly as I imagined if you have any dimensions you could PM me with to save me some time I could get something started sooner than later and if they work out ok I will send you some

Bengrim09 · Nov 7, 2016

Had some bits back from my " laser cousin " 2 lower crown pieces and enough pieces for a pair of side linkages, not 100% happy with them so they need a little tweaking then I shall knock together another pair

Kroenen77 · Nov 8, 2016

Bengrim09 said:
hi buddy nice to hear from you again
it's funny you should ask about this part, as I'm in the process of drawing this up and making a mould, as im going to make some from melted aluminium. With work being so busy I'm not finding enough time to get it done as quickly as I imagined if you have any dimensions you could PM me with to save me some time I could get something started sooner than later and if they work out ok I will send you some

PM sent.

Bengrim09 · Nov 8, 2016

Kroenen77 said:
PM sent.

let me see what I can knock up I will keep you informed

Kroenen77 · Nov 8, 2016

That would be great.But it must be very very thin.Hope you can do something.

Bengrim09 · Nov 19, 2016

Scratch built a jaw key from aluminium just need to refine it give it a good polishing up then make 4 more, when I've got all 5 I'm going to cast them into a silicone mould, smelt some aluminium and try to recast them.

MAKE 4 more !!!!! I don't think so, I will just cast this 5 times, what was I thinking

Bengrim09 · Nov 19, 2016

Kroenen77 said:
Wow great stuff that you made!
About the fabric:Its a lot darker in real because the pics are made with heavy flashlights.This is a big problem with most of the pics from the revealmask.
Do you have a lasercopy of this part?It should be made of very,very thin sheet.My vovoder is near finish..but without this part I cannot glue it in the mask.

http://up.picr.de/27367836kw.jpg

Going to try and have a go at the very very thin piece that sits on top of the vocoder tomorrow, going to cut a template first

Kroenen77 · Nov 19, 2016

Great work and news.I will finish my facemask tomorrow.So the next step is the lower jaw also.

Bengrim09 · Nov 19, 2016

Kroenen77 said:
Great work and news.I will finish my facemask tomorrow.So the next step is the lower jaw also.

Post some pic buddy

Kroenen77 · Nov 20, 2016

Will do.I really hope that you can build a great part with this thin arms!

Bengrim09 · Nov 20, 2016

Scaled this drawing up today 3 times bigger to make is easier to draw then I will reduce it back to the correct size on the printer, printed on sticking paper so I can stick it straight onto my thin plastic for cutting out as a template for my aluminium mould

Kroenen77 · Nov 20, 2016

Looks great.

Bengrim09 · Nov 23, 2016

Kroenen77 said:
Looks great.

Well mark you've certainly set me a task
printed it to scale on sticky paper and placed it on 0.5 mm plastic and started to cut it out with a scalpel !!! But it's just a little harder than I imagined
This one is now classed as a fail and I'm going to try and cut it out of something a little more sturdy may be Very soft aluminium sheet, plastic is a little to soft and can't get the little blobs correct near the ends

But I will not be beaten

Bengrim09 · Nov 23, 2016

Got my jaw key cleaned up ready for moulding

Kroenen77 · Nov 23, 2016

Wow that looks awesome.Is it not possible to laser the master out?This fine arms are really a nightmare to cut with hand!
And how do you print out with the right scale?What programm do you use for that?

Bengrim09 · Nov 23, 2016

Kroenen77 said:
Wow that looks awesome.Is it not possible to laser the master out?This fine arms are really a nightmare to cut with hand!
And how do you print out with the right scale?What programm do you use for that?

Can't laser cut as my laser cousin explained the fine lines would probably burn with the heat with his works laser
I got it to scale by drawing it 3 times bigger then reducing the size by 33% on my printer
spoke to a RPF member tonight and he gave me another option I'm going to explore over the next few days sounds very promising if the costs are acceptable I'm going down that route
and I will probably get a few made for other builders to keep the costs down
i will keep you informed

Ben

Bengrim's Darth Vader reveal project

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