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  1. Too Much Garlic's Avatar
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    Oct 30, 2017, 6:11 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #26

    That's a really cool project and coming along nicely.

    Where did you get that 3D file? Looks awesome.
  2. RPF Premium Member 13doctorwho's Avatar
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    Houston, Texas
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    Oct 30, 2017, 8:28 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #27

    I can not believe how cool this is. I can't wait till it's done!!
  3. CT1138's Avatar
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    Chicago
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    Oct 31, 2017, 1:54 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #28

    Oh man, this is really coming along! It looks great!
  4. daredevil665's Avatar
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    Jun 2013
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    Emilia Romagna Italy
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    Oct 31, 2017, 2:30 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #29

    Beautiful and intriguing work!
  5. xenobiologist RPF Premium Member Leigh's Avatar
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    Cambs, UK
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    Oct 31, 2017, 3:44 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #30

    Awesome!!
  6. iloveyouiknow87's Avatar
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    Oct 2017
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    Rome ,Italy
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    Nov 2, 2017, 5:08 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #31

    amazing job man!!!!!!
  7. RPF Premium Member jess the pirate's Avatar
    Member Since
    Oct 2014
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    Nov 12, 2017, 4:33 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #32

    You could always coat it with cassini's plaster, or any P.I.P for that matter, that way you could cut out the pva glue stage altogether. It's made for outdoor sculptures and its pretty damn cheap. Also whilst its kicking you can add the little details like the stan cast has, i.e pits and whatnot. Just a thought! Keep going, its pretty amazing already and the teeth supports is a genius idea! Well done!
  8. RPF Janitor RPF Premium Member Lear60man's Avatar
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    Nov 19, 2017, 3:11 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #33

    Ya know......this is the type of thing that you could make a good chunk of change once finished and presented correctly.
  9. ChickenHaunt's Avatar
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    May 2010
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    Los Angeles
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    Nov 19, 2017, 4:25 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #34

    Really nice
  10. Barking Dragon's Avatar
    Member Since
    Dec 2007
    From
    Australia
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    Nov 20, 2017, 3:31 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #35

    Outstanding work mate loving how this is coming together
  11. Howat Props's Avatar
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    Apr 2013
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    Glasgow, Scotland
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    Dec 8, 2017, 9:41 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #36

    wow! this is going to look amazing! I would love to make this myself
  12. ShareAHack.com RPF Premium Member shareahack's Avatar
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    Jan 2015
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    Dec 12, 2017, 3:02 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #37

    Thanks all for the feedback! It's been a little bit harder working outside as the weather got cooler but I've made a bit of progress since the last post and have since moved the project indoors.

    jess the pirate said: View Post
    You could always coat it with cassini's plaster, or any P.I.P for that matter, that way you could cut out the pva glue stage altogether. It's made for outdoor sculptures and its pretty damn cheap. Also whilst its kicking you can add the little details like the stan cast has, i.e pits and whatnot. Just a thought! Keep going, its pretty amazing already and the teeth supports is a genius idea! Well done!
    Thanks Jess for the great idea to use plaster! I think I'm going to attempt a combination of plaster + cheap clay over the foam on certain areas before applying the resin/fiberglass. I'm hoping the plastered areas dry with cracks (I may try to induce the cracks somehow) to better simulate the look of fragmented bone.

    Here's a few more progress photos of the lower jaw and beginnings of the mounting system. I decided to keep the mounts super simple and easy to disassemble for transporting around.

    I hot-glued some temporary wooden braces/supports to the lower jaw to maintain rigidity while building the mounts. For now, the base is just a piece of MDF with 4 castor wheels on the base. The skull will appear to 'float' over the much smaller base.



    Here I cut out a small cavity in the top of skull and epoxied in a piece of plywood with a cast iron flange screwed on to it. I slathered epoxy and polyurethane glue so that the glue would puff up and expand into he foam cavities. Once In place I jammed a bunch of the bamboo BBQ skewers in and around the wood to reinforce and spread the tension over a wider area. I then added more poly glue to firm everything up. A 1/2" black iron plumbing pipe will do most of the work holding up the skull. This main connection point will be reinforced later with fiberglass mat and resin.



    I hoisted the top part of the skull up with a rope to more easily balance it in position over the base:



    I used another scrap piece of pipe and a decorative flange/cover thing I found to act as the base's pipe holder that mates with the iron pipe:



    To hold up the lower jaw, I machined these little side-mounted connectors that are fastened to the sides of the jaw in 4 places. I mounted them on plywood so they have a firm base to hang on to instead of just the foam. Later on these connection points will also be reinforced with resin/fiberglass. The chicken wire was just an afterthought and I figured it might help with grabbing on to the fiberglass/foam.

    Smaller steel dowels run through the pipes that will connect to t he side mounts. The mounts have set screws tapped into them to hang on to the dowels when in place.



    And here's a look at what the final orientation/positioning will be! I can modify the height, position of the jaw, and how open the mouth is just by changing the lengths of the iron pipes.



    Every now and then I post some progress/videos on Instagram if anyone interested: https://www.instagram.com/shareahack/

    Hope everyone is gearing up for a great holiday! Cheers
  13. RPF Premium Member 13doctorwho's Avatar
    Member Since
    Jun 2012
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    Houston, Texas
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    Dec 12, 2017, 4:52 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #38

    God, I love this project. I am super jealous!
  14. CT1138's Avatar
    Member Since
    Nov 2016
    From
    Chicago
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    Dec 12, 2017, 5:38 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #39

    It's really taking shape into something gorgeous!
  15. daredevil665's Avatar
    Member Since
    Jun 2013
    From
    Emilia Romagna Italy
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    516
    Dec 13, 2017, 1:36 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #40

    Compelling work! I like solutions. I am eager to see more progress!
  16. Barking Dragon's Avatar
    Member Since
    Dec 2007
    From
    Australia
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    Dec 13, 2017, 6:27 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #41

    It's really coming along now, great progress pictures as well
  17. ShareAHack.com RPF Premium Member shareahack's Avatar
    Member Since
    Jan 2015
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    44
    Jun 28, 2018, 3:38 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #42

    Happy Jurassic June!


    Sorry for the delay in posting...it took a few weeks (off and on) but I'm happy to say the fiberglassing is finally DONE!


    I waited out the winter and moved the project outside into a car shelter to avoid any possible VOC problems from the epoxy and dust particles from the fiberglass.


    I decided not to mess with any polyester resin (yet) due to the risk of melting the foam. I used almost 3 gallons of epoxy to cover the entire surface area of the skull.


    I ran out of the original 2 gallons of counter top resin I had so I decided to buy smaller batches as I needed it to finish the fiberglassing.


    The second type of epoxy I tried was West System (way more expensive but clearly superior than the counter top stuff...cures extremely hard and more sandable).


    When I ran out of West System, I tried some cheaper "Envirotex" brand that I found at Michael's (the 50% off coupons didn't hurt!). To compare, 1L of West System was around $80 (with hardener) and the Michael's stuff was around $30 for the same volume. The cheaper brand cures slightly more "rubbery"/flexible but it was perfectly adequate for finishing off this stage of the project.



    I used a combination of fiberglass mat and woven cloth. Lost track of how many sheets I bought but it was quite a few (maybe around 10 sheets of 8 sq feet - so around 80 sq feet was needed to coat the whole skull.



    I started with the hardest part (the teeth) and laid down the glass strips in a combination of ways (lengthwise, spiraled around the tooth, etc).



    I removed the wooden supports from the lower jaw and drilled/tapped a couple of metal corner brackets to act as a linkage to connect the left and right lower jaw pieces with a single screw.



    Before fiberglassing the rest of the skull I started with reinforcing all the metal mounting points and linkages.



    The mat was more epoxy-hungry than the cloth and it took a lot to saturate it but it was perfect for molding around awkward shapes and crevasses. The woven cloth helped to bridge the mat and add good structural reinforcement.



    Sometimes the fiberglass wouldn't 'stay down' very well especially when it was hotter outside. My solution was to lay down the glass in position as best I could, wait a couple hours for a bit of curing to take place and then push down the parts that were springing up into the foam - this worked out well because after a few hours the resin has more of a putty consistency.


    A cool little tip I found out: After laying down a strip of glass, the little left-over strands/resin on your gloves - you can work them into a little ball and use it like a putty/filler to cover up an exposed area or hard to reach place.



    Finally everything is coated and extremely durable...I'm hoping it will last forever! Next I need to clean up all the sharp fiberglass spillovers and knife-like edges.



    A full timelapse of the fiberglassing (condensed to 1 minute) can be watched here:


    https://www.instagram.com/p/BkcQ5Ewh...-by=shareahack


    Thanks for reading!
  18. Too Much Garlic's Avatar
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    The dictatorship of Denmark
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    Jun 28, 2018, 4:23 AM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #43

    Looking awesome. Looks big and menacing.
  19. tarnyloo73's Avatar
    Member Since
    Jun 2017
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    89
    Jun 28, 2018, 2:40 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #44

    Great project and looking good. Must make one for myself one day.
  20. Lunajammer's Avatar
    Member Since
    Jan 2013
    From
    Fargo, ND
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    67
    Jun 29, 2018, 3:16 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #45

    I admire your knowledge and mastery of the materials. Your commitment to the project is also admirable and the results are fantastic. Really looking forward to seeing where this ends up. Nice work and thanks for sharing your techniques.
  21. ShareAHack.com RPF Premium Member shareahack's Avatar
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    Jan 2015
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    4 Weeks Ago  Jul 12, 2018, 7:10 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #46

    Decided to spend some time reinforcing the teeth... I figure the teeth will be the first thing my nephews want to run up and grab. The fiberglass has made them pretty strong as-is but I want to make sure they can withstand the full force of a group of 5 year olds

    I found a bunch of scrap threaded rods, screws and metal dowels:



    I measured/cut the rods to length and sharpened them all to a point:



    For the threaded rods, I made little slots to be able to use a screwdriver to drill the rods down below the teeth tips:



    Now time for the root canals...I drilled holes in all of the teeth to get the metal rods seated:



    Drilled the rods deep into the skull, passed the "root" of the teeth into the skull. For the small teeth I just used regular long construction screws:



    Quick video of the process here: https://www.instagram.com/p/Bkx5Uhih...-by=shareahack

    Next I'll be shaping the tips of the teeth with bondo and probably covering them in more resin/fiberglass.

    Time to stop procrastinating and start cleaning up / sanding the fiberglass (I've been dreading this part!).

    Cheers
  22. animator's Avatar
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    Apr 2011
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    4 Weeks Ago  Jul 15, 2018, 7:36 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #47

    This is just the best project ever!

    I showed this thread to my son who loves dinos and he said, "Daddy, you couldn't do that." ...reality is harsh
  23. ShareAHack.com RPF Premium Member shareahack's Avatar
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    4 Weeks Ago  Jul 15, 2018, 8:41 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #48

    Thanks @animator! Honestly this is the first project I've ever done like this (my first time using resin/fiberglass too). Somehow got the idea and just had to pursue it as I'm sure everyone here can relate Jury's still out on what the final product will look like lol
  24. tarnyloo73's Avatar
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    Jun 2017
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    4 Weeks Ago  Jul 16, 2018, 6:03 PM - Re: Full Sized T-Rex Dinosaur Skull - advice on coating/finishing/painting rigid foam #49

    Good call making the teeth nephew proof. Kids are masters of incidental demolition

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