https://www.blindsquirrelprops.com/work daily 1.0 2022-07-27 https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565272013-DY0X5S3WDWY46V9YLF1I/BPRD0001.jpg Projects I was commissioned to make a replica of Hellboy’s gun from Mike Mignola’s comics. Mike’s style is very simple so there wasn’t a lot of detail to base the plans on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565272155-9HPMZU6WJC9PYLVZQCBW/BPRD0002.jpg Projects The client had attempted to make one himself so had already bought supplies and an airsoft gun. I based my plans on this gun so that I could make parts that fit the same model for a kit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565274321-ANZ1OHHCBIOH4MAITPX4/BPRD0003.jpg Projects The client had also purchased real wood grips for the prop. He had already removed the gas chamber from the gun so I had to reinforce the grip frame with a block of poplar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565274677-VJ0YYQ9F14PCOGEY9XCA/BPRD0004.jpg Projects The barrel on the donor gun was too long so the first order of business was to modify it to fit the plans. I removed the orange tip and popped off the front sight for later use. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565276525-6TR6LI0WS6805X6BRDSH/BPRD0005.jpg Projects I used the Dremel cutting wheel to remove about an inch off the end of the barrel and removed a spring (not sure what that was doing in there…). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565277442-GQBFAR8WZ4LM06L94MWB/BPRD0006.jpg Projects The new barrel would be formed by an acrylic tube. I would’ve like to keep the airsoft functional but the new barrel wasn’t going to line up with the old one. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565279523-SBG58R8N2RNQ0VPWEQZX/BPRD0007.jpg Projects I marked the location for the sight rail on the tube and scored the cutting path with a blade. I used a board as a straight edge to keep the path parallel to the length of the tube. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565282641-97T72W0GO0HH0EO60Y15/BPRD0008.jpg Projects Using a cutting wheel, I removed the a slot. The edge had to be cleaned up with files. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565284334-DZX9IJL6RZCRCYIIJA5N/BPRD0009.jpg Projects The tube in place. The sight rail was too cool not to use. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565285995-QG153VV93OR9UYBEB2GZ/BPRD0010.jpg Projects To keep the gun properly aligned in the tube, I made some MDF spacers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565286533-GXR8FA0ZEASUTFDP6N7L/BPRD0011.jpg Projects To make the end of the tube flush around the curves of the gun’s frame, I used a contour gauge to transfer the profile to poster board. This was then used to trace the shape onto a piece of MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565289228-U6GARXO1OKO5C98XN1NK/BPRD0012.jpg Projects The remainder of the tube was used to make the cylinder covers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565289924-HK1AMW2MHZDVN36TPT7M/BPRD0013.jpg Projects The client also supplied acrylic domes which I cut to fit the tube edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565293669-PLHH0KPE5A3L1Z7507CK/BPRD0014.jpg Projects I taped the pieces together and epoxied them from the inside. The wood stick makes sure the spacing is right. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565294019-FVPANKOJXFSOSU57JJOT/BPRD0015.jpg Projects Putty and sanding removed the seam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565296765-FK3FYRZU7HEQZSF3Z0DK/BPRD0016.jpg Projects To figure out how big the barrel should be (and by extens the bullet that it shoots), I cut black poster board to show the client. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565300361-LS6M1RY75DIVGNTCLCRX/BPRD0019.jpg Projects The .75 caliber made the barrel look like a silencer and it wasn’t until you got to 1.25 that the thickness of the metal looked appropriate as a gun barrel. This thing would fire one big, monsta-killin’ bullet! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565303208-U5G4I6WVWIB79R8TTPP6/BPRD0020.jpg Projects For the supporting pieces under the barrel, I cut MDF and a wooden dowel for the (non-functional) hinge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565303391-1LLTBONF8YB3FAT9L5TA/BPRD0021.jpg Projects I drilled out the ends of the dowels and glued in the binding screws that the client sent.   https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565305402-23DO44MXQ4NKKNHJMD9W/BPRD0022.jpg Projects With all the big pieces added to the airsoft gun, The trigger guard was looking a little frail. I cut some MDF and used Bondo to make a snug fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565308444-E7LXLX7TG1597IHJECJ6/BPRD0023.jpg Projects In prepping the grips for the prop, I had to carefully drill holes into the these expensive wood pieces. A hole was drilled under the grip for the lanyard ring. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565309989-Z8HS74EWADKF1B4CZGPO/BPRD0024.jpg Projects It killed me to do it, but I used a forstner bit to cut a hole for the B.P.R.D. seal. Fortunately, it cut cleanly without beating up the diamond pattern. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565313188-CVE5Z92ZGM5CCUJ263QR/BPRD0025.jpg Projects I experimented with using a PVC pipe for the barrel but with such a large bore, the pistol was looking like a flare gun. To remedy this, I modeled a rifled barrel in 3D. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565312849-NLD3HQY6FX8MXCJ2Q6X2/BPRD0026.jpg Projects A few weeks later, Shapeways sent me a beautiful barrel insert. I modeled it about 3-1/4″ deep so that it would have the illusion of being longer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565315291-4232P508UFYZRJRXZ8MU/BPRD0027.jpg Projects I drew out a template that would allow me to glue in the insert centered in the acrylic tube.   https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565316294-KTAXEI94FRHEEH1J2AEQ/BPRD0028.jpg Projects I had the BPRD seal for the grips laser engraved out of plastic. I molded one and cast duplicates in resin. I heated them so that they could be curved like the grips. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565317807-08VEX9YX6P7MP34L1FNJ/BPRD0029.jpg Projects Now that the grips had been modified for the prop, I molded them to make resin copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565319483-9MDZHIE2QPCI4QWT4SVR/BPRD0030.jpg Projects For the kit, I needed to make an insert to strengthen the frame of the airsoft gun. I sprayed the frame with mold release and then glopped a ton of Bondo into the space. Once it cured, I was able to pop out a perfect insert. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565321304-93KG3RSHNLDX0S753SNH/BPRD0032.jpg Projects The cast plastic frame insert. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565323394-7EASBEWU2QO2Y0DK5X3C/BPRD0033.jpg Projects used a Dremel cutting disk to remove the bottom of the airsoft barrel so that it could fit into the new barrel frame. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565323705-3J6D1SGTN8ZU54SRALV9/BPRD0034.jpg Projects In order to mold the new barrel assembly, I needed to fill the cavity so that the master (and any copy) could be removed from the mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565326876-PWK1LVHCRRLMJ84MEYXU/BPRD0035.jpg Projects I covered the gun in plastic wrap, poured some expanding foam into the cavity and then seated the gun. The foam expanded and filled the inner space. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565327313-LCCJ51X790PRH9UGFU2D/BPRD0036.jpg Projects As the expanding foam is the same as the epoxy resin, there was a real chance of glueing the gun into the barrel assembly. Fortunately, I was able to remove the gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565329444-DVIOL73QGCG3R6ANAR14/BPRD0037.jpg Projects To make a mold of this piece, I had two choices. One involved cutting the piece down the middle for two 2-part molds or keeping the master in one piece and making a 3-part mold (two sides and an end plug for the barrel). I wanted to keep the rifling whole so I chose to do the 3-part mold. I sealed off the end and poured each side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565329907-U1VCZUH2QSRAEPON76VF/BPRD0038.jpg Projects After the sides cured, I poured the end. This was a tough shape to mold and I ended up breaking the master just de-molding it. I also had air bubbles in recesses that would not have been a problem if I had cut the master in half. But, in the end, I have a working mold…no use crying over spilled milk. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565332098-ABBCZ80VSDFGE5JL4CCN/BPRD0039.jpg Projects The first cast from the molds. Good outer finish with only minor cleanup in the inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565335030-42HTBFRED0EEIOSNAMFB/BPRD0041.jpg Projects It’s a tighter fit than I expected due to minor resin shrinking but a little work with the Dremel fixes that. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565335781-WM2SUUV08MF0N126D1O5/BPRD0042.jpg Projects I mixed brass powder into my resin to cold cast the B.P.R.D. seals for the grip. They were shined up by buffing with 000 steel wool. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565337805-WWNBMZXUZENY6TAD41GJ/BPRD0043.jpg Projects The last thing that I had to do to the donor airsoft gun was remove the seams from the frame. I used spot filler putty on those as well as the manufacturer’s engraving. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565338907-EVRJ0VRXOOQ7IGQBSUFT/BPRD0044.jpg Projects The client was getting his original wood grips so I had to paint my resin copies. I started with a base coat of dark brown. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565340591-E30AVC9FKC2YCUFVL1AT/BPRD0045.jpg Projects I used an old sock to brush on wood grain with black acrylic paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565341628-C8WT40ZD42YCW4QD8TAM/BPRD0046.jpg Projects I painted the Smith & Wesson logos gold and sprayed a protective top coat of gloss Crystal Clear to finish them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565342913-LI3NBUD7JUQRVWLBMS0X/BPRD0047.jpg Projects I airbrushed the inside of the barrels with a gloss black model paint. An airbrush is able to get into tight spaces that a can of spray paint can’t. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565344201-GUGAMKXDO0GFTKI1EUYD/BPRD0048.jpg Projects All the metal parts were painted with Testors Metallizer Gun Metal. After it dried, I buffed the paint to a sheen. The gun was finished by dry brushing silver to bring out detail and add simulated wear. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565345070-3PHK88V9J8EKV9KAD5YH/BPRD0049.jpg Projects The final gun. The heavy resin barrel gives this replica a convincing heft! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565346427-VJEGY6IU7CZUPEP90UPB/BPRD0050.jpg Projects The client’s gun is on top, mine is below it…the difference being the painted resin grips. I’m happy to have one more item in my Hellboy collection! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565349013-ESRCXFOFEUNL7K42WTW2/BPRD0052.jpg Projects Grip detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565349718-2WQTJ11SHTES406HSRYJ/BPRD0053.jpg Projects Frame detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565351611-80AW3PCMUQQXVXJBTIHG/BPRD0055.jpg Projects Muzzle detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565353325-NCZ2Q1J8EQNAGL1OPJ3O/BPRD0056.jpg Projects Trigger detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565354021-97NP55TH25XEI1RP6ZOE/BPRD0057.jpg Projects Hammer detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522565354216-GFZQCGE22D71H9H19VPL/BPRD0058.jpg Projects I was able to get my replica signed by Hellboy creator Mike Mignola himself at a local convention. He was nice enough to say that it was the best replica of the gun that he'd ever seen. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630399151-EEYAAWX628T6HNZ6CE47/MPH_eyes0001.jpg Projects A client wanted accurate eyes to replace the ones on this toy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630399268-9YC6CPNSZFD0M3S76J3A/MPH_eyes0002.jpg Projects The eyes are joined on the toy and should be separate. Not to mention those weird eye brows.... https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630404011-I826UWHZZG8HAQBO57WN/MPH_eyes0003.jpg Projects I shot a photo of the toy and drew my template from it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630401719-M9OGURFMQUJJKHFG0PR9/MPH_eyes0004.jpg Projects I sculpted the new eyes and brows in Strata. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630407033-LQLS91H39VQTQ6LSBPLT/MPH_eyes0005.jpg Projects These are the prints I got back from Shapeways. The mounting pins on the eye brows turned out to be too thin and risked snapping off. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630408521-AYR0LEAEG4QX7NFPC69D/MPH_eyes0006.jpg Projects I re-sculpted the brows with a thicker peg (old one in black above). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630409720-G0X0DZ3C1ULMGRDUUGHN/MPH_eyes0007.jpg Projects Painted parts with black vinyl pupils. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630410641-E9SOOCE55ED5IHV0ZYP2/MPH_eyes0008.jpg Projects I made alternate eye brows so you can mix and match for different expressions https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630412059-H3GNR4N9GMZRGLYWJIC2/MPH_eyes0009.jpg Projects Not sure how to read this expression....skeptical? https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522630413283-VAW53B78NK6QCGR02QG8/MPH_eyes0010.jpg Projects MPH back home! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227516820-RZLBSHPM20Y1BDXIE7I4/TS_Tinkertoy_0001.jpg Projects One of my clients wanted Woody's Tinkertoy cannister podium. He bought a vintage can that had the right lid but the can was too tall. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227516753-QZ1SH162BOR86P23Z8UL/TS_Tinkertoy_0002.jpg Projects This is the original 1993 can as shown in the film. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227523047-2KQAEYU9LFZADREFQ021/TS_Tinkertoy_0003.jpg Projects The source can came with a ton of parts that I could use to re-create the illustrations on the label. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227522226-PZEH36HG7TWBZ3LC9ENV/TS_Tinkertoy_0004.jpg Projects This, according to the label, is a "boat". I'm not seeing it… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227525968-L3K56TZ1UEV3OFUY7ZH9/TS_Tinkertoy_0005.jpg Projects As a graphic designer, re-creating this label was right in my skill-set. I had it printed on vinyl at a local vendor. I later re-printed it on matte stock that more closely matched the original can. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227526363-THMUKSBTSPOVBRIJSLZU/TS_Tinkertoy_0006.jpg Projects After wrapping the giant can, I could cut it down to the proper height. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523228505492-T1XLFUAODS89HW3Q66II/TS_Tinkertoy_0010.jpg Projects I made a mold of the original can. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227533266-M8Q1TZS35E8ZISILA4OR/TS_Tinkertoy_0008.jpg Projects I also molded the lid, intending to slush cast copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227535830-4ZDGU1ZYZEX8SM8Z3YCE/TS_Tinkertoy_0009.jpg Projects The copy is on the right. It's a little too red but I can adjust the color easy enough. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227557708-ZOAJM31HM5OGZ91KA8TW/TS_Tinkertoy_0020.jpg Projects I cold cast the can with aluminum powder so that it shines when polished. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227544630-QTJNIHYWACZGSXO1GGFU/TS_Tinkertoy_0013.jpg Projects The recess for the lip of the can filled in while slush casting so I whipped up a jig for use on the drill press. Unfortunately, it just wasn't precise enough to preserve the thin lid walls. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227571971-D6VNXO762Q1DZC5NYKM1/TS_Tinkertoy_0023.jpg Projects I gave up on making the lid lock onto the can but it fits nicely on top and looks right. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227579766-JBLP3W1HU11WKU4ZUNJY/TS_Tinkertoy_0024.jpg Projects I lined the edge of the label up on the edge seam and wrapped the vinyl around the can. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227583259-37XOKE0ZCHH2ZEQYP5L3/TS_Tinkertoy_0025.jpg Projects The final can. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523227583461-DRDBBR9GU08WKFXCHT11/TS_Tinkertoy_0026.jpg Projects It's meeting time…gather the toys! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230774348-WMKM3RT8MOFIBXDEJNO1/hedonismbot-0001.jpg Projects One of my favorite characters from Futurama is Hedonismbot. How can you not love a robot so decadent that he is his own couch? https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230774654-9ESMOH9M1BPY854648LP/hedonismbot-0002.jpg Projects After drawing the basic parts in Adobe Illustrator, I imported the paths into Strata 3D to build him. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230778169-NYB5M6S0MY7F8R8L3IDS/hedonismbot-0003.jpg Projects 3D printing the entire couch at Shapeways was going to be pricey, so I just printed the edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230777173-3LJ0XQSDG1LRX8SB762J/hedonismbot-0004.jpg Projects I completed the couch with pieces of basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230781344-2LNM0QA9Y5A77TGX9OEC/hedonismbot-0005.jpg Projects Once the seams were filled with putty, I prepped the surface with filler primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230783042-BM3UZG87MUM2Y759ORGQ/hedonismbot-0006.jpg Projects A resin copy from the mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230784435-OH6R05TJQXCRSRAUNEVJ/hedonismbot-0007.jpg Projects Around this time I bought one of these beauties…The FlashForge Finder. The rest of the parts were printed on it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230785454-ZI2UJVMKP42GQ3R47O3I/hedonismbot-0008.jpg Projects It's hard to tell with the supplied translucent PLA filament, but the prints are almost as good as what I was getting from Shapeways. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230791561-8PJGTXWVRFRZFLPQC21N/hedonismbot-0009.jpg Projects The remaining parts with a coat of filler primer. You can still see some print marks but a quick sanding removes most of them. The cleanup is very easy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230799381-MRA5L8HS68W81RK9UTON/hedonismbot-0014.jpg Projects Test fit of all the pieces. After a little more cleanup, it was time to make molds of the parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230804256-BUPM4FK8WRVU5PEBPIPP/hedonismbot-0016.jpg Projects First resin copies out of the molds. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230803419-VFQQ2GDO0EEQPA3J59QA/hedonismbot-0017.jpg Projects To hold the bowl in place without gluing, I inserted a chunk of broken magnet inside the belly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230806360-T47MHLSVB2JVZUORWRY6/hedonismbot-0018.jpg Projects Another chunk of magnet was added in side the bowl. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230810966-1WSXOPZCRD5MJV2SPMWO/hedonismbot-0019.jpg Projects The grapes were glued into the bowl, covering the magnet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230810635-H65PC8DU1ZGJKMSCO9MG/hedonismbot-0020.jpg Projects The bowl now sits magically on HB's belly! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230814859-9UEGNECQ1QSHMDWH294N/hedonismbot-0021.jpg Projects I printed a vinyl sticker for his mouth. I also glued on his laurels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230813519-SM5OXNVGECJP7I5HJKUX/hedonismbot-0022.jpg Projects After painting his eyes, Hedonismbot is completed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230817363-XYXN1YA2NVKM3DFY3MD2/hedonismbot-0023.jpg Projects How decadent! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523230818749-V2TT798FPQG91X4KZYV5/hedonismbot-0024.jpg Projects Hedonismbot on his shelf, with the other Toynami figures. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232086894-CO5H8P4UVVQL5I7MGWWP/Rohan_Spear001.jpg Projects Karl Urban as Éomer with a spear in the background. I was able to cobble together enough reference from various shots in The Two Towers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232084720-B8WC1UQJSYAEDDSF8Q9S/Rohan_Spear002.jpg Projects After drawing up full size plans, I turned the central shaft on the lathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232100193-RUE2S7G2JJ8LLKDOYHXN/Rohan_Spear003.jpg Projects The blade profile was cut from 1/8" plywood. I used balsa wood to frame out the high ridges of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232099445-X8YRZE0GHACNSG6IJGBA/Rohan_Spear004.jpg Projects I spread Bondo between the ridges to form the curved channels on the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232110468-BFTBGY2RDST15G8VC41U/Rohan_Spear005.jpg Projects The completed shaft and blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232111619-Q2N81NDQ8PX478CN9S75/Rohan_Spear006.jpg Projects The shaft has two decorative rings around it. Strata can map the pattern around the ring but the geometry would have to be built from scratch. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232121924-OX8VIT8NU6HLIHZFJNWR/Rohan_Spear007.jpg Projects A kind soul on Facebook with more sophisticated software was able to model the ring for me. The other one I sculpted and printed at Shapeways. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232121271-3FI7K7CSL8OKO5TIYTP6/Rohan_Spear008.jpg Projects The decorative rings test fit on the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232130726-SCJFHLLFIHRFVD8PWMJX/Rohan_Spear009.jpg Projects I cut away the parts needed to join the shaft and blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232147264-BSGL00923LY002P4WJJU/Rohan_Spear010.jpg Projects Test fit of the blade on the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232137965-ECKCMG9KDNLCMT63E6N0/Rohan_Spear011.jpg Projects I masked off the edge of the blade and used Bondo to complete the tip of the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232150834-VIMLK8MBWOY64JDA3JGO/Rohan_Spear012.jpg Projects Bondo was also used to fill in the seams. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232196580-1PKE3SAZ476JBJICBP4A/Rohan_Spear013.jpg Projects A coat of filler primer completes the spear head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232206827-35HOF6JZERSO7OQIZSUW/Rohan_Spear014.jpg Projects The spear head on a clay bed, ready to be molded in silicone. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232205875-K6J0EW9DGIIQUK01MF3Y/Rohan_Spear015.jpg Projects First side done and clay removed for molding the other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232222864-93TPZZEQ9BHTSO5W8IS4/Rohan_Spear018.jpg Projects A cold-cast resin copy of the spear head fresh from the mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232229999-IJR2LLJTXWFEY7ICCLN5/Rohan_Spear020.jpg Projects After the spear head was polished with steel wool, I painted the decorative rings. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232241756-1M03HX86I3U9YSHQGTRL/Rohan_Spear021.jpg Projects A wash of black acrylic paint brings out the details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232238838-BEQEGEJT576QQT21GSGL/Rohan_Spear022.jpg Projects The completed and polished spear head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232256675-7E034JEU7FIPCFJPW7W2/Rohan_Spear023.jpg Projects I used a forstner bit to hollow out the end of the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232256785-2P2JH827LI4WK47VDLLE/Rohan_Spear025.jpg Projects I narrowed the end of the ash spear shaft to fit inside the head. I also added a threaded rod for a more secure joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232272259-9FLFMCC84EU5H63ANOVB/Rohan_Spear026.jpg Projects The spear head glued on the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232265975-X0L9KVFRUS6CJKJZQNJ8/Rohan_Spear027.jpg Projects Finally, the wood grain was brought out of the ash with stain. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523232272046-YC2Y0ASRWEYP2G5TX5W1/Rohan_Spear028.jpg Projects The final 9' spear on display. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233472163-32Y5LEAI9EMNS9TF8XK8/Judge_Death-0001.jpg Projects British comic artist Brian Bolland is the designer of Judge Death and one my favorite illustrators. I wanted to build my helmet based on his design. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233432445-7QUX17MC9YZQATVLDJOL/Judge_Death-0002.jpg Projects I drew out a plan on my helmet template. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233437649-6S9CXM17T9R87XHMVNKY/Judge_Death-0003.jpg Projects I pulled my plans into Strata3D, sculpted the helmet and then imported it into Pepakura. Once it was printed on cover stock, I assembled the paper model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233486536-TWKCIYUZZ4OOVMH1RQ61/Judge_Death-0004.jpg Projects I then slushed a few layers of resin inside the paper model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233486531-4KZBXD9WHE1JCHUAR6EA/Judge_Death-0005.jpg Projects I then sanded off all the edges and smoothed out the angles. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233490951-SV1KYFPQI6YSXT56TBQU/Judge_Death-0006.jpg Projects A coat of primer shows you how much work you still have to do! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233493938-BDW8S3MBIFWUSRXVRX9S/Judge_Death-0007.jpg Projects More smoothing and I scribed the thickness of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233496630-A5R9U0W6TMF8LQHIL7V8/Judge_Death-0008.jpg Projects I cut the spikes of the portcullis visor out of thick styrene plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233505953-ZWPLZV6ZHLSE4PQHN19D/Judge_Death-0009.jpg Projects But once I placed it on the curve of the helmet, the spaces between the spikes were too wide. This was a lesson in the difference between two and three dimensions... https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233507611-8IV0250DN6S9I3SW05B3/Judge_Death-0010.jpg Projects Measuring the actual distance the visor takes, I stretched the plans to fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233522980-GZP4Z3J4N0SK4F1UHP7N/Judge_Death-0011.jpg Projects I cut new spikes from styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233553458-X91NE0LUWRCAODHBKJ51/Judge_Death-0012.jpg Projects You can see the difference in width between the old spikes and new. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233552650-BUK62G9G1LOV4ACN7UF8/Judge_Death-0013.jpg Projects With all the spikes cut, I glued them to the crossbars. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233564835-WY356DY0S1463GR04QSJ/Judge_Death-0014.jpg Projects The final helmet and visor get a coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233594154-8DI2GB2UEEOF9B92HQAH/Judge_Death-0018.jpg Projects I couldn't find any rivets the size I needed so I added epoxy putty to round-headed screws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233593826-L92FD5XKF2VCUFGVA1R4/Judge_Death-0019.jpg Projects The excess putty sanded down. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233628581-8OL0IMKQ7WLOAFDA4CSX/Judge_Death-0021.jpg Projects I measured the centers of the spikes to glue on the rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233617795-6OPGEVB4NVK4CII4FRI0/Judge_Death-0022.jpg Projects I molded the visor and cold cast a copy in aluminum. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233644392-P1H7TKXDHQR00YG06L3V/Judge_Death-0023.jpg Projects I applied a black acrylic wash before buffing the surface with 000 steel wool. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233639740-HESZ3MMCZILM5QU2ANHF/Judge_Death-0024.jpg Projects The painted helmet with visor applied. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233643517-VXUCFR96T2PZANGCCZJG/Judge_Death-0025.jpg Projects Since a Deadworld Judge wouldn't have a pristine helmet, I added scuffs, scratches and rust. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523233646909-6Y071E1JI0VUAJ99PI3W/Judge_Death-0026.jpg Projects I also added a sprinkling of dust and dirt. The eventual goal of this project is to sculpt a bust for this helmet to sit on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130387378-TLIQZ3JNKF8L3V5PS877/JD_Bust-0002.jpg Projects About a year later, I pulled my plans into 3D and sculpted the bust of JD. It was heavily based on Brian Bolland’s artwork and I took reference from mummies and desiccated corpses. I was inspired by Giger’s Xenomorph design in that it had no eyes. That’s just plain creepy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130390939-9M9AVOML3H2W3DQL28QD/JD_Bust-0003.jpg Projects I printed out the model, glued the parts together and test fit the helmet. It sat on the bust perfectly without need for any padding! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130391308-TAMCD6SYSXOP753JOFJZ/JD_Bust-0004.jpg Projects The base was printed separately and connects to the bust with an aluminum tube. I filled the base with plaster to give it some stability. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130394432-4POK5OJXG8TQUTL1M1DL/JD_Bust-0005.jpg Projects I bought a sample kit of Smooth-On’s XTC. It’s made to fill in the print lines of 3D prints. It took two coats to get a smooth surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130394541-T9O6EQ8595474AQOCRFM/JD_Bust-0006.jpg Projects It sands pretty easily though and only leaves a few dings that can quickly filled with spot filler putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130397515-DIS9V2P7KRY1XHKEPNIZ/JD_Bust-0007.jpg Projects The downside is that it will fill in small detail as well so I think it’s best used for organic shapes. I had to redefine the teeth, lips and gums before laying down a base coat of white with an Xacto blade https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130397961-19FZ15RSUYIC5WDR0X03/JD_Bust-0008.jpg Projects Next I painted the teeth, gums and base skin color. I used pictures of tooth and gum disease as reference …a fun afternoon of research. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130403367-EQCCX8RHQ2B0AJW3ITN2/JD_Bust-0009.jpg Projects Then it came time to airbrush shadows and definition to the skin. Since I painted the base color from a rattle can, I was concerned with the darker shade matching. I’m horrible at mixing color. I ended up spraying more of the base color into a jar and then adding enough black to darken it slightly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130403827-7V6CYLPIS422XXPDCH28/JD_Bust-0010.jpg Projects To make his uniform, I needed to make a pattern. I started by covering the skin with plastic wrap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130406311-O0HEHODNST8LDDDIT765/JD_Bust-0011.jpg Projects Then I wrapped duct takeover the area. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130407410-MVQXDCJCIGM7TUVOSK31/JD_Bust-0012.jpg Projects I cut the duct tape off and wound up with a pattern for the collar and top of the jacket. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130409439-HVJL16P2JR722C9E1I1M/JD_Bust-0013.jpg Projects I cut a piece of EVA foam for the base and contact cemented it to the edges of the shoulder piece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130410423-WM2WVK6VNARD2WJ82A66/JD_Bust-0014.jpg Projects The foam jacket after glueing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130412522-P61N1QNLOF8DEWXR0COR/JD_Bust-0015.jpg Projects I then attached the collar in the same way. I heated the foam with a blow dryer and, when it softened, smushed it against his body until it cooled to simulate skin tight leathers! The foam was painted with two layers of Angelus acrylic leather paint. I punched holes in the edges after reinforcing that area by glueing black t-shirt strips to the back. This would keep the holes from tearing once the laces were added. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130414202-DHYGXSF2C6DOYOVBM7N9/JD_Bust-0016.jpg Projects The final bust! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529130415943-FY2NIU35S9L9O00G555G/JD_Bust-0017.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234860165-B2EOCBH793S86N9DA436/AlanMoore_001.jpg Projects I am a big Simpsons fan and collector so a Simpsonized Alan screamed to be made into an action figure for my collection. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234859862-HK30T8LQVA0DXT3NTF8B/AlanMoore_002.jpg Projects The episode ends with Alan, along with fellow comics writers Art Spiegelman (Maus) and Dan Clowes (Ghost World), ripping off their shirts to reveal their superpowers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234861531-RRFW3953US7WJKT3814U/AlanMoore_003.jpg Projects I bought an extra "Ripped Groundskeeper Willie" to use as a base for the new figure. I will be replacing the head and hands (due to Alan’s rings) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234862372-MYWEJOXPNF93FQOTMD5K/AlanMoore_004.jpg Projects After drawing up a template from screen caps, I started to sculpt the head. It's important to rough in the major shapes before the geometry gets too complicated. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234862471-4J7Z5UGL2G5A01TCOGNF/AlanMoore_005.jpg Projects Face sculpted. Fortunately, I only have to sculpt one side…the geometry is mirrored automatically. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234863837-Z46TAMLI5YUYY61MKH71/AlanMoore_006.jpg Projects Final head and hair sculpt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234865987-NIB5AHX4CXFA2XU7SCYV/AlanMoore_008.jpg Projects Sizing this one was a real problem. The first print of the hands from Shapeways were too big! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234864801-AZUWA45LMZ8FDLABKR3T/AlanMoore_007.jpg Projects The head came back too small. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234879552-G9JHNM5GR6K1Z9Q77RPO/AlanMoore_016.jpg Projects But the mistake allowed me to do some maths and get the size right on the second try! Here is the new print, sprayed with filler primer and polished. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234886764-78YCMDMH8NSBD1Z637J1/AlanMoore_018.jpg Projects I cut off Willie’s hands and glued the new hands on with JB Weld epoxy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234886431-ZOQVGN2Q2QI0BZKL0XPG/AlanMoore_020.jpg Projects After glueing on the head, a coat of primer checks the progress. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234891174-AEWQWI61V5MWIVIPZJN4/AlanMoore_021.jpg Projects Next I needed to change the belt buckle to match the drawings from the show. I cut away the extra plastic and later added a small piece of styrene to make the tongue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234889380-4OXO7YFV5UNGUB9WPEF9/AlanMoore_022.jpg Projects I also had to remove the cuff from the pants and restore the seam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234896717-2QWV7T9JY0A9EBFTPIZJ/AlanMoore_023.jpg Projects I also had to re-shape Alan's shoes https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234896173-QT4M4BFDYPUJ22N0G8NK/AlanMoore_024.jpg Projects I had originally intended to mold the figure as one piece, but I changed my mind. I cut of the arms and used bits of steel bar to make pegs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234901996-5KLO1V7AEZ7JODG50W1K/AlanMoore_025.jpg Projects I made a clay bed to mold the figure. Bits of wood make pour spouts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234903516-5L78H4G85G2PFB9TIUQ3/AlanMoore_027.jpg Projects I played with mix ratios to dial in a proper Simpsons Yellow in the poured resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234906150-DO27ZL9ZCJ1TIXV1JH5B/AlanMoore_028.jpg Projects The first copy from the molds with proper color. I’m very pleased with the seam. Very little cleanup. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234907670-7BYM3RTVJ9H0HBOQC8H3/AlanMoore_029.jpg Projects I hand painted his rings (under extreme magnification) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234918591-3XYH8JY1W0PBPWWF7P0L/AlanMoore_031.jpg Projects Alan’s hair, beard, eyes and mouth were also painted by hand with acrylic craft paints. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234923118-R14UV3OX5GJGKEE6WSB6/AlanMoore_032.jpg Projects The pants, belt and shoes were painted a flat black. The belt and shoes got a coat of semi-gloss clear coat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234926147-BJSAGDYVCXJ514UCY9JS/AlanMoore_033.jpg Projects I glued Alan’s arms in a spell-casting/ Sith lightning pose because he is awesome. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523234929684-DCBWULRAOAR5XPOJEJ3I/AlanMoore_035.jpg Projects ALL HAIL THE MIGHTY ALAN MOORE! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524287314242-ZWKJL5R5QKAS54KLIUON/michelangelo-0001.jpg Projects I absolutely love the 2012 Nickelodeon series Teenage Mutant Ninja Turtles. Beautiful animation, great designs and genuinely good, funny stories. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251158574-N7Q5CYJ9AHYVLYNV8VBG/michelangelo-0002.jpg Projects This is an accurate representation of me seeing the life-size Michelangelo toy. It just needed to be more accurate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251162664-B4HPSRFKC5GEM845RBEL/michelangelo-0003.jpg Projects He disassembled pretty easily. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251161235-NO2UX22JDXH9HA0ELZBL/michelangelo-0004.jpg Projects I found some close colors in standard acrylic craft paints. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251163295-11NS6M8PE8MA35Q7AQI0/michelangelo-0005.jpg Projects I used white Krylon Fusion spray paint as a primer. Its formula bites into the plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251168641-8VC9DW9QF4ZLKNJT0BIE/michelangelo-0007.jpg Projects Base coat on the belly plates. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251173551-F0KN7RQTMIFO1HWGD1B1/michelangelo-0008.jpg Projects I applied a lighter color along the edges of each plate and in the scratches. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251171626-DQ3LUMY67A8501GL9OQR/michelangelo-0009.jpg Projects Base coat green on the shell. The plastic actually has some nice detail molded into it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251174348-8DE0L4P4RZRH6SABTNZB/michelangelo-0010.jpg Projects A couple of layers of shading gives the shell dimension. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251179834-U10Q45B9JDMD7BBMSIT8/michelangelo-0011.jpg Projects The inside of one of the fingers was missing a part. Since it was too late to return it, I patched the hole with styrene and Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251176927-MGZ1DE5HL6JFV278PO8D/michelangelo-0012.jpg Projects To remove the seam and mold marks, I sanded and used filler putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251180361-3MONZS9KT1CCPCVCVSD9/michelangelo-0013.jpg Projects Base coat for Michelangelo's skin which I had custom mixed at an auto paint store. It's super expensive ($30/can) but sprays on so nicely! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251182762-G62C2BSMIR0NAHBCCZHE/michelangelo-0015.jpg Projects I cut stencils from card stock and used it to paint the soft splotches of green on his skin. If you hold the mask a few inches away, you get a soft edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251186116-9TXPPKZQEG5I2YP6XL50/michelangelo-0016.jpg Projects Another mask was used to paint the spots. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251186667-TIJ8TK103346JIVUYVMV/michelangelo-0017.jpg Projects I masked off the side of the torso and painted the base color. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251190416-IIVCZNDUJEVYB9DLZ614/michelangelo-0018.jpg Projects The finger wraps had a nice texture that I could bring out with a wash of black acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251189669-A2OQPFTUGE88NPSY6DC2/michelangelo-0019.jpg Projects The wraps back on the painted hands. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251195364-OLP77L1ZFJPBKD09D6LU/michelangelo-0020.jpg Projects The wrist wraps were painted by masking the edges of the molded geometry then airbrushing and sponge texturing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251192750-01NF2EK5KBIFFB78DL3B/michelangelo-0021.jpg Projects The painted and re-assembled legs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251195476-2NRG09JO1DCEIKYXZ955/michelangelo-0022.jpg Projects I added metal rivets to the elbow pads since they neglected that detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251198300-7VBHUS1EY97FKYIFHPO3/michelangelo-0023.jpg Projects I cut stencils in Frisket for the stitching on the elbow pads. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251199271-NCXBB2E6UPPH24AK7A0S/michelangelo-0024.jpg Projects The final elbow pads. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251203735-9E809643JGU4BEIU842C/michelangelo-0026.jpg Projects The completed body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251207839-5MFVC6KDLICMLLQA2PBQ/michelangelo-0027.jpg Projects A year later, Jakks Pacific came out with Michelangelo's brother, Leonardo. As tempting as it was to work on him as well, I had to finish Mikey first. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251211184-QRSIX4E4QZ938HA1AG02/michelangelo-0028.jpg Projects I had some scrap Kydex plastic that I was able to heat form into his nunchaku holsters. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251210771-5M9E7SSTDOAUT2SCYV3H/michelangelo-0029.jpg Projects The supplied nunchucks were horrible! I had to re-build them from scratch. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251215072-1SJLF7JVSUOW6IVCN8HL/michelangelo-0030.jpg Projects I lathed the new sticks from basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251213880-4YBIU4UUIPGH7F75JASF/michelangelo-0031.jpg Projects I carved out the diamond pattern with an Xacto blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251216826-Y2V1S208JF0TTH3VXP7H/michelangelo-0032.jpg Projects I made a mold from the master and cast resin copies. They were then painted gold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251219044-Y1B57OS73YO406U5MPE9/michelangelo-0033.jpg Projects The gold areas were masked off and the brown leather areas were painted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251221924-F5V6AOJK3IJMPIJ24RU7/michelangelo-0034.jpg Projects I made a chain swivel from styrene which would be connected with half of a chicago screw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251221871-M6RK1N65SQP4YCQAOVEX/michelangelo-0035.jpg Projects I had links laser cut from acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251225625-KIBOQZDGKYANUUU1Y17H/michelangelo-0036.jpg Projects After making a mold, I cold cast aluminum copies. A bit of polishing gives the links a real metal sheen. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251225072-V3OK2DE4LX01DSJF5THE/michelangelo-0037.jpg Projects To link them into a chain, I heated the resin to soften it, cut it with a blade and then glued the joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251231525-AFJ3QBPD034SSNKQM9EM/michelangelo-0038.jpg Projects The completed chains. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251234380-41D90TM76OU9JRU1REG8/michelangelo-0039.jpg Projects The last link on each end goes through the swivel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251234622-44W6WEZB1V1KENJLBGY4/michelangelo-0040.jpg Projects I cut a foam insert for the holsters. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251237267-2RCASJIJ0USGV6LCMXID/michelangelo-0041.jpg Projects I cut a foam insert for each holster. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251243857-7GQ57JEEK4U3HIME6SOI/michelangelo-0042.jpg Projects The nunchaku in the holster. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251240399-WA54D1L46E492KXAUM8M/michelangelo-0043.jpg Projects The head had horrible stickers for the eyes and a crummy rubber mask that would need to be replaced. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251243855-1QLA23DRPSWAHM7D2X6T/michelangelo-0044.jpg Projects I trimmed out the mouth to make a more sculpted replacement. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251247252-YR15RO3OR0P3N0L16B9G/michelangelo-0045.jpg Projects I drew in the areas where the new eyes would go. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251246431-IBLJRMQOGWYYTPU8FNTV/michelangelo-0046.jpg Projects Eye holes trimmed out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251249882-PQADURIDYW1XMGWI5E1C/michelangelo-0047.jpg Projects I added some masking tape behind the eye holes… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251252592-9B8ZAV9FIW6TL1W35476/michelangelo-0050.jpg Projects …which kept the Bondo from sticking to the head. The Bondo which squished through the holes would become the new eyes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251255478-UTTJIYMNAR4HAD6YMW5Z/michelangelo-0051.jpg Projects The new Bondo eyes after a bunch of sanding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251264324-WY88JYVW0MZWHDLYCDFJ/michelangelo-0055.jpg Projects I cast some plastic eyeballs, placed them in the head and marked the location of the pupils. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251266445-SIJHQTCQZ1ION3MSX8NT/michelangelo-0056.jpg Projects I bought some acrylic doll's eyes to use for the pupils. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251271686-ROQ3FKW8E3WDUUPRQUZQ/michelangelo-0057.jpg Projects I trimmed off the old eyeball, keeping the pupils. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251270236-5H34AHLR84V6NUMXNWC6/michelangelo-0058.jpg Projects I used a forstner bit to drill a hole in each eyeball. The new pupil just slides in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251261956-190C11QKHB0S4KP8IY30/michelangelo-0053.jpg Projects I smashed some clay inside the head and sculpted a new mouth and teeth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251261620-P7SWBI7JZBCWB3MQW69Q/michelangelo-0054.jpg Projects The plastic copy from a waste mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251272623-13YFEP97V3O4TZ0XHKVE/michelangelo-0059.jpg Projects After a lot of cleanup, I painted the replacement mouth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251274282-KT13EAM94SRVZ7IZA95A/michelangelo-0060.jpg Projects The new mouth glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251278943-FS5VEVCKUS5K31FAMMO5/michelangelo-0061.jpg Projects And the head now with new eyeballs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251286029-6WKE36K3SD0IBKYVEVU5/michelangelo-0066.jpg Projects I used some newsprint to make a template for the mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251286444-MFS3JYVDV1ATJZXTRQ6O/michelangelo-0067.jpg Projects I bought some EVA foam to make the new mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251292057-H87AXH7IMUWCBA0T6R76/michelangelo-0069.jpg Projects The new mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251291826-MQZICA5QDGEEKAJVXS5I/michelangelo-0070.jpg Projects As simple knot holds the mask on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251297407-WVK1UYYYHMXFUBYDYL3N/michelangelo-0072.jpg Projects Before and after. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251298127-6PAXF0R97GYG57EBFNJ6/michelangelo-0073.jpg Projects Before and after. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251301243-OAYX3S7C20LJ1028IAOC/michelangelo-0074.jpg Projects Before and after. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251300864-JID8MN718HGXWYO6ZH0Y/michelangelo-0075.jpg Projects Before and after. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251304253-CDPK8R38WY7W00SQQXVK/michelangelo-0076.jpg Projects Before and after. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523251303683-J8TVMCT4JYY3BJ0ARGOG/michelangelo-0077.jpg Projects Before and after. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253449837-FWLAA8LH6HNK0YXC9F2K/arakh_0001.jpg Projects There's so much cool stuff in Game of Thrones but I really love the Dothraki swords. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253458564-OEQ280IYTXXIFFVBKRT8/arakh_0002.jpg Projects I based mine on Khal Drogo's sword but I tweaked the curve of the blade to something more pleasing to my eye. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253458077-F9PJ8EEOY9LJJO9FHG48/arakh_0003.jpg Projects I glued a few pieces of poplar together to form the profile. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253470142-0J525KB35K1BKNSSWLHC/arakh_0004.jpg Projects The basic shape cut out and the start of the edge of the blade (formed on the belt sander.) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253474078-V65EG6V2C153YYSLIIQU/arakh_0006.jpg Projects The hilt is very thick so I cut out two more pieces of poplar for the sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253473817-JR01H1CGEJN7LXT29XA4/arakh_0007.jpg Projects I bolted all three pieces together and started carving. Some Dremel sanding for material removal but a lot of hand carving with an Xacto blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253482009-Y7Q5NKFQWUDNANZ0GGWQ/arakh_0008.jpg Projects Carving the hilt while the blade was attached was cumbersome so I cut out a tang for the blade from the middle slice. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253481226-U05B8P1708T8SENV0NIS/arakh_0009.jpg Projects The three piece could be glued together for refinement of the shapes. I also build some shapes with epoxy putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253486570-8UKUH36P6AGJ8Y7GBF8H/arakh_0010.jpg Projects Some of the round decorations could more easily be made on the lathe. I used basswood for its fine grain. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253484230-Y3MGZPCGPO1VS9H39J95/arakh_0011.jpg Projects These pieces slid on the tang of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253487232-FILTK363YUDI4WMARUWT/arakh_0012.jpg Projects Test fit of all the parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253493732-Q741LFGM8R1879YNGOV1/arakh_0013.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253489340-1AQIZ52V5OFE0TK6Q6HG/arakh_0014.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253498435-N0Q77ZSVG49H6KB4G8JS/arakh_0018.jpg Projects Final painting of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253502039-1JXXXUNQP9DY7FKR9G5L/arakh_0020.jpg Projects For a gem on the base of the blade, I carved a master from basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253505532-FXA4UOZCL6ECV7RFUIC9/arakh_0021.jpg Projects I molded it and cast a bunch of resin copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253504841-AADPTS8ZIE8B6P0ZDU69/arakh_0022.jpg Projects I cast a bunch of these shapes for the blade as well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253511593-G29C0Y643NA5769IPJUP/arakh_0024.jpg Projects I cast some clear gems from the molds. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253511585-K89EZ6AHKBGMSGSEZOTU/arakh_0025.jpg Projects An acrylic gem was glued into each side of the pommel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253997653-NBGZYMAYHGO71UPRV6HY/arakh_0030.jpg Projects Decoration on the base of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253515196-ZOXC98T38TX18AQOBJTV/arakh_0027.jpg Projects The final sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253518365-NIQ6WHPD8OZJ94FQOPA9/arakh_0028.jpg Projects Detail of the hilt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523253518069-LWN634R76V5NTOWI2P47/arakh_0029.jpg Projects What a wicked blade! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510083644-PVD73CFAXK5IWN246GOZ/KOTH_Cotton-001.jpg Projects I am a huge King of the Hill fan and one of my favorite characters was Hank’s father, Cotton. There was a limited run of action figures but no Cotton! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510086660-5SBETU2NKA8O1EGOCQYV/KOTH_Cotton-002.jpg Projects I found the original model sheets for him online. You can’t ask for better reference than that. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510086614-FST268R0O0MR4CCXGYHL/KOTH_Cotton-003.jpg Projects I made a front and side profile vector illustration from the model sheet. These views were imported into Strata to model the figure. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510091142-GZKM8HR3A9D1JSXDXAWZ/KOTH_Cotton-004.jpg Projects I started with the head to test out the 3D printing. I was hoping that Shapeways’ full-color Sandstone would be a good solution. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510091499-SX4G6T4OJGQCPWGYSPTP/KOTH_Cotton-005.jpg Projects Here is a test print in the Sandstone. The resolution is a little rough but at arm’s length, it has a nice natural feel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510097179-N0HNL6DQIY97E6XT30WT/KOTH_Cotton-006.jpg Projects This test also allowed me to double check my measurement. Cotton was as tall as Hank before his injury. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510100961-61SUZQ2ZROF0LZFPCXGG/KOTH_Cotton-010.jpg Projects Here is the final model. I sculpted all the body parts separately to make it easier to adjust the polygons, flip symmetrical parts and export each part for color mapping . https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510110008-VVAF9ZUPPX85ZMYSAGAP/KOTH_Cotton-012.jpg Projects Overall, I am very happy with the results. Obviously, resolution will get better and cheaper to produce, so one day I will reprint the figure. For now, I’m super happy! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510108957-V2HJ9LEMKI472ERCBGG4/KOTH_Cotton-013.jpg Projects Detail of this handsome devil! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510116642-BMKN0NPYF0HTDR4SFIN6/KOTH_Cotton-014.jpg Projects His poor shins! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510116946-UZT01F1Z6W0R3VCEO63M/KOTH_Cotton-015.jpg Projects To cut down on cost, I made the torso and legs hollow, adding holes in the bottom of his feet to allow unused material to be extracted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510120525-FS8YB9Z5K60AF7KBL6OJ/KOTH_Cotton-016.jpg Projects Cotton with Hank and Bobby, for scale. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523510122422-8KJ056BV0ZNQM64LR632/KOTH_Cotton-017.jpg Projects The whole crew, so far! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511396544-R27ZMOJKVEIZD7TNQ77W/Theoden_0001.jpg Projects One of the coolest helmets from the Lord of the Rings movies was King Théoden’s. Because of the insane amount of detail, I went into the project with the mindset that it was a long-term project, to be worked on when there was nothing else going on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523512222592-GRM480Z1K81JR2I5ML90/Theoden_0002.jpg Projects The first step was to draw out a detailed plan of the helmet. This started out pretty loose…I would continue to update this as I went or found new reference. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523512228165-ZUQA2J820DUE6U3U7HXP/Theoden_0003.jpg Projects I imported the side and front profiles into Strata3D and sculpted a simple model of the base helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523512249867-3DOLYUTKMCM0HYSMEOPE/Theoden_0004.jpg Projects I ran the model through Pepakura and assembled a paper version. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523512273335-UKKERS61AGC9R8TMHRUN/Theoden_0006.jpg Projects After slushing Smooth-On Smooth-Cast 300 plastic resin into the paper model, I sanded off the edges to start smoothing the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523512273342-J1EZNQYKC67PZ6YRFSJV/Theoden_0005.jpg Projects Because the paper model flexes, it was important to brace the geometry when I was adding the resin inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523512299433-9JSRDSGS1APMBCAYSI7D/Theoden_0007.jpg Projects Bondo smoothed the geometry further and corrected any geometry issues. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511416872-QM5EQ7GAVAQK9UXOTTXQ/Theoden_0009.jpg Projects I used more Bondo to refine the back edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511415072-STCHWRRZX1IOTVALGDJ2/Theoden_0010.jpg Projects To make the raised bands that run down from the top of the helmet, I stacked up nine layers of masking tape and placed them on either side of the band areas. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511417334-3D2VQU2Z3FQY8LKG3CNS/Theoden_0011.jpg Projects Bondo was squeegeed between the tape barriers using a flexible piece of plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511421069-SUJH6YJG89QJNA32L7AK/Theoden_0013.jpg Projects Once the tape was removed, the resulting bands are a consistent height. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511424964-HJ13TI9E3LFWGKA6766L/Theoden_0014.jpg Projects I cut the back edge into segments with a Dremel cutting wheel. I wasn’t very happy with the results and later changed the slot to a flatter angle and rounded the segments more. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511425765-J6HS4INQHCBA2LPE68TV/Theoden_0015.jpg Projects To make a template for the crest, I taped small pieces of cardboard together along the profile. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511428268-MK6ULW7Z82RR31K7S55Y/Theoden_0016.jpg Projects This was traced onto a piece of MDF and the rest of the crest was transferred over with carbon paper. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511432097-U5Y6PEQH0AFA50KUO5UX/Theoden_0017.jpg Projects A test fit of the trimmed out 3/4″ MDF crest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511431356-1U2A6YK9TWJIQIMLVR35/Theoden_0018.jpg Projects I refined the edges of the helmet with Bondo and added a Bevel to the eye holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511443661-4XTNES14WTJM2ZAH7J7C/Theoden_0022.jpg Projects I used the tape and Bondo method to build up the horizontal edge around the helmet as well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511440896-UXHFA0DE2BD4NPH33IG7/Theoden_0023.jpg Projects The nose piece needed some correction to match the curve of the original. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511443870-FPAP3N5FLO8LX8ZLE18S/Theoden_0024.jpg Projects I bought half round styrene strips to apply to the raised bands. For some reason the flat edge of the half round strip is not actually flat. This causes problems when you try to glue it down. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511447521-LB5KT7JLF2PB5NVOU4W6/Theoden_0025.jpg Projects To fix this, I use a Sharpie marker to draw on the flat side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511447477-ZXYKGBL1901XGUPOBGCX/Theoden_0026.jpg Projects Then I use an Xacto blade to scrape the side flat. When the marker is gone, you have a flat surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511451384-X5EIZR44AESV8V9LTIJK/Theoden_0027.jpg Projects The strips could then be glued to the raised edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511450362-4Z3IIBWL2YVBSHMYQFT2/Theoden_0028.jpg Projects The nose guard has a raised triangular profile which I defined with a piece of plastic along its center. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511455578-9FUHZ1IE2LK1XCKH5QJ5/Theoden_0029.jpg Projects Bondo was spread between the raised center profile and the edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511454631-4UHBQ2AMKUTN14SVQNPF/Theoden_0030.jpg Projects I added detail to the eye bevels and glued thinner half round to the inside of the eye holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511459324-AF14T2CMVA25BV2L79C2/Theoden_0031.jpg Projects Back on the crest, I carved the details of the horse using my Dremel tool and Xacto blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511469890-NJQXIP2D6V7J0JES0WD6/Theoden_0037.jpg Projects Once the right side was done, I traced templates of each section onto clear plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511473425-9F70M65NGQ5QC0UPHSS8/Theoden_0038.jpg Projects These were flipped and traced onto the other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511481169-TIBN7P2G59EFFBI19FK8/Theoden_0041.jpg Projects Then simply carve the other side to be perfect symmetrical! Now that I think about it, it would have been much easier to do this in 3D. Next time, right? https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511484650-0FANLUUKPNMWSI414M3E/Theoden_0043.jpg Projects Since it would have been super hard to sculpt, I cut a link from a spring for the ring on the horse’s forehead. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523513879371-QNXM7ZURBDSJNDRVSE8L/backbutton.jpg Projects To get the detail while still being symmetrical, I opted to make the decorative elements with Strata3D and then upload them to Shapeways for printing. Click for a time lapse of sculpting the “back button”. It actually took about 90 minutes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523514030227-MZW2OWFVTA3G2HHYUPOT/Theoden_0046.jpg Projects I received my first 3D printed part from Shapeways. Since I wimped out and didn’t model all the detail into the arch, I would have to add it before duplicating the production parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511494925-SIHF8F1R4XQI7VBCQ7NL/Theoden_0047.jpg Projects I carved the top into segments, added a scribe line and rounded the triangular pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511505932-BQ1CIKNQESS8ZJJ2BBOV/Theoden_0051.jpg Projects I added a second level of half round to the face so I could make a template for the center detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511510141-GM31EG2WMB7TEN9Y7461/Theoden_0055.jpg Projects A quick coat of primer shows the progress so far. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511514137-DUFZ9LW5K2CSOOJIE7WY/Theoden_0056.jpg Projects The back button back from Shapeways. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511516566-RL02V4USZZWSAU9HKJQM/Theoden_0058.jpg Projects More 3D printed parts arrived from Shapeways. I used the polished option so a coat of filler primer and a quick sanding allows it to be molded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511523094-IKGGHHSZ3SKHAXMCJWM6/Theoden_0061.jpg Projects All pieces were cold cast in brass. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511525812-WNBHIDMSK8ZS8IKK4XG9/Theoden_0062.jpg Projects I printed out the plans and taped them to the helmet to double check decoration sizes before sculpting them in 3D. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511525425-3W6DPR4GNFEW02E4BLKJ/Theoden_0063.jpg Projects To make the recessed pattern around the brim, I covered the area with masking tape. A print of the pattern was taped in place and I cut all the shapes with an Xacto blade. The print and excess masking tape was removed to reveal the pattern. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511528075-YXCPO4AM79CDQRI2XDWD/Theoden_0064.jpg Projects The design went all the way around the helmet. that's a lot of cutting! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511530448-8YPC7O2TKSEX2NOEUHPZ/Theoden_0065.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511535950-9AH2DM7WWNE006REEXKY/Theoden_0067.jpg Projects More 3D printed parts back from Shapeways. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511538474-8Q2V4SFB5P7OO26TN0QL/Theoden_0068.jpg Projects The band pattern would be too long to print as one piece so I printed halves and glued them together for a master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511538367-5EW0NN0UXJ8IVTIQW8B0/Theoden_0069.jpg Projects Resin copies were bent and glued before the resin fully cured. At that stage, the plastic is solid but still flexible enough to bend or distort around complex curves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523655912307-29DDKIRFI502G8XF1L13/Theoden_0085.jpg Projects As you start to add detail and see how everything fits together, you discover your mistakes. It wasn’t until I started to glue down the triangular decorative pieces that I saw how my “W” piece needed to extend further between them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511584730-HZLP1ECFW4V9GQCGWXI0/Theoden_0087.jpg Projects I traced a template onto a piece of clear plastic. I scanned this in to correct the 3D model which was uploaded to Shapeways for a new print. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511627624-7JFNC5F6RGLK6CZJIUPC/Theoden_0101.jpg Projects A few weeks later, I got the revised W, which I molded and made resin copies to glue to the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511626586-1FYAH0QLBEJPMP45KWMZ/Theoden_0102.jpg Projects Much better! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511644081-VNCZTNML7B9C1KLOAAN0/Theoden_0109.jpg Projects Of course, once that was in place, I noticed that the arches don’t line up with the middle triangle and center of the W. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511643948-1X9XS4AF7NRF8Z5TAOAJ/Theoden_0108.jpg Projects I pulled off the arches and cast new copies, this time trimmed and glued in proper alignment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511654195-7DZEFE1EG7SG6UKX3FC0/Theoden_0110.jpg Projects A final coat of primer shows me all the flaws that need to be fixed before it goes into silicone. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511654057-O1WLYMKVC54AAGWW9DQ3/Theoden_0112.jpg Projects I used scraps of light cardboard to create a barrier for the silicone by hot glueing them inside the opening. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511657148-6KAJCCRRKQPBZC2MNNNT/Theoden_0113.jpg Projects A thinned coat of Smooth-On Stroke silicone captures all the detail and allows air bubbles to escape easily. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511658530-C0PEA41223U8739OT34M/Theoden_0114.jpg Projects Several coats of Stroke later and keys applied to the final coat. I taped more cardboard to “trace” the profile of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511661831-DBX7USPFSKERF20QDC8P/Theoden_0116.jpg Projects This “tracing” was used to cut out two plywood pieces that would bolt together the halves of the mother mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511665456-8Z4IELRLR2LS0TBNRV6V/Theoden_0117.jpg Projects After the mother mold cured, the whole thing was disassembled and the master could be de-molded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511665457-UW7SGPZF2C77Q8LKNKOH/Theoden_0118.jpg Projects Reassembling the mold, I slush cast a first layer in cold cast brass, followed by thicker layers of black tinted resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511668932-D4W6YUEJVNRYCNHU4WOO/Theoden_0119.jpg Projects The de-molded first copy! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511679132-UO3YR0W0KMMG9A2SX9DQ/Theoden_0124.jpg Projects The side stripes needed a copper background. I hand painted them (with a small brush) using Testors metallic copper model paint. It was not as hard or as time-consuming as you might expect! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511699784-ZENJZR5Y9LSNMAGLJK4N/Theoden_0126.jpg Projects I didn’t feel like masking all that detail to spray paint it, so I broke out the Testors metallic silver model paint and hand painted two coats. The first coat on the left still showed brush strokes and some brass underneath. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511746972-A0GIHI8JCUPH1FTZYOIT/Theoden_0128.jpg Projects All the other pieces were epoxied, using drive screws (threaded rivets) to pin them in place. I applied red acrylic gems to the front and back pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511619373-NUSG21J0OXZYBUOFWTYF/Theoden_0099.jpg Projects While all of the molding was going on, I used fun foam to figure out the size of the back leather armor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511629836-Y8135QXJRJDVVLNCYODA/Theoden_0103.jpg Projects I scanned these pieces and used the image to lay out the pattern for the stamping. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511676675-G0VQHPE6TRQ4CD93N5LX/Theoden_0123.jpg Projects I sent the file to the amazing Lee “Fevereon” Camara in Atlanta and a few weeks later I received this beautiful leather piece! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511742985-RWEDMNYCX9NWXZKNZNNZ/Theoden_0127.jpg Projects I epoxied chicago screws into the back edge of the helmet to attach the leather straps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511756077-7D1QCVW0KFKNBHK8ZPA7/Theoden_0129.jpg Projects The final helmet https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511774422-18H2K4SOSL52YPGYQDPJ/Theoden_0130.jpg Projects I applied a wash over the helmet to add weathering and bring out detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523656610218-8JMUQ7TA1BQ6G1IJGSHH/Theoden_0137.jpg Projects Other color details were also painted by hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511767519-QDUV49RJQ47RH2ZVJBQ2/Theoden_0131.jpg Projects The leather armor really looks great against the brass. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511776037-TM4QU6URP77KWJJRSTN2/Theoden_0132.jpg Projects Crest detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511812866-6Q930IXORS4TE7NDA5YO/Theoden_0133.jpg Projects Back button detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511887741-T6NGGQ42NV0CKSP6LHZX/Theoden_0136.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511800560-B269I6BT5M67F7NKQ0XJ/Theoden_0134.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511828840-J7RRS0HI39AY8PR0A5OC/Theoden_0135.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523511911860-39MT4UNIU47KZUAVG6RK/Theoden_0139.jpg Projects I slush my helmet a bit thick so it barely fits on my admittedly giant noggin, but it’s mainly a display piece so I’m fine with it. Let’s hunt some Orc! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685423310-FGZHHPFADT54UQ97830X/mempo_0001.jpg Projects The 2013 movie "47 Ronin", starring Keanu Reeves, featured some beautifully designed Samurai armor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685420245-IB48QUFWJ888CF3MM610/mempo_0002.jpg Projects My friend Paul bought one of the film suits but it didn't come with a mempo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685423325-MNEE85VVU7ZAJSUPC3M7/mempo_0003.jpg Projects We researched actual mempos and used this one to base the new one on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685425765-IDPLEYSNEPCHQWOS79JZ/mempo_0004.jpg Projects I drew a template for the new mempo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685426581-I59QJA95P066UGO26DE2/mempo_0005.jpg Projects Based on the front and side views, I sculpted the mask in 3D. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685435182-ZIGR3ZMNTXJU8L94W5YW/mempo_0006.jpg Projects Refined geometry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685430478-0HD0B0SEFOAIFU5LCGKS/mempo_0007.jpg Projects To double-check the measurements, I printed out a paper model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685447261-4RO42JU6HS95R1UKSA4R/mempo_0010.jpg Projects The model was printed at Shapeways, then further modified with epoxy putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685457287-UQDRFI7N2LO0CDHPTDGV/mempo_0011.jpg Projects In addition to a rolled edge, I added a decorative grommet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685460783-7BSY22SJLG3VFO8PSMF4/mempo_0013.jpg Projects A silicone mold was brushed onto the master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685465704-PQH2LU4Z2UW2RP7CWO9E/mempo_0014.jpg Projects My resin copy of the mask gets epoxy putty fangs. Grrrrr! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685471323-2QP6B8D4106PV5NDM5FJ/mempo_0015.jpg Projects Weathering and ribbon straps added. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685472261-SMZ55N9KXC95OZ64VQDC/mempo_0016.jpg Projects Front view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685476970-JUGZG41LQY29L357T2T4/mempo_0017.jpg Projects View of the inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685478392-Z1BITJKB8O2TUU3S8KM9/mempo_0018.jpg Projects Scary! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685486485-2BC0ZON3HYMV7NG3NGI8/mempo_0019.jpg Projects Paul bought horse hair to add to his mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685488635-2ZH3L4WYOSHYUSX3IXF3/mempo_0020.jpg Projects We drilled holes for the moustache and beard and threaded hair through them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685496220-IN5W3NBPT3RJ6KZE4POM/mempo_0021.jpg Projects The hair was pulled inside the mask. Dig the antique gold inside! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685492326-MNMV1X0ZEYTL11JKE1XB/mempo_0022.jpg Projects Paul used epoxy putty to secure the ends of the hair. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685505893-XUL4AM3OQ0F4CI9136D9/mempo_0024.jpg Projects The putty was smoothed to become almost imperceptible. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685504745-FWL6TM9AIV45AWBW4ALW/mempo_0025.jpg Projects The final weathered mask. The hooks on the sides allow the helmet to be secured. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685515772-MPGEGW1UYE9A26A43SAJ/mempo_0026.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685512788-SWZV093QSVVLUQ4QT6PI/mempo_0027.jpg Projects Top view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685533063-JBZX9D4CQ1XQBO08JPDG/mempo_0032.jpg Projects 3/4 view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685517739-APDRTI1ZQ58RUVDWC08H/mempo_0028.jpg Projects Inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685523879-ZY4UB3CW8BWVB6C3T2R0/mempo_0029.jpg Projects Detail of the teeth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685523869-IRHXG5VO69R8FIEFO2AJ/mempo_0030.jpg Projects A hole under the chin allows sweat to drain out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685537176-FFOZWZJW48THP17BRT9K/mempo_0033.jpg Projects Detail of the grommet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523685542105-IVTQUINIWAFLGA4IS3Q2/mempo_0034.jpg Projects The mempo with the rest of the suit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748814371-PZ4KXLJPTU5QE55GAIVY/SJS_0001.jpg Projects This is the SJS helmet from the Judge Dredd comics. A few members of the Judge Dredd costume group on Facebook wanted a Dredd (2012) movie-style helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748813505-HD23CBFI6A9FX2FTIIZ8/SJS_0002.jpg Projects I sketched out a few options to try to bridge the basic design of the comic with the look they established in the film. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748818550-2ELLM9SC7R4JWYYBCCM6/SJS_0003.jpg Projects This was the final approved concept. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748829099-8AKD8E8KI9MGRZFA94AQ/SJS_0005.jpg Projects I built the helmet in 3D and then converted it to a paper model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748830107-CCJBIO2ZLBAK1RJ01SOW/SJS_0006.jpg Projects I slushed resin on the inside of the model to build up a solid interior wall. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748832367-H681XBWKG2L826U8NY06/SJS_0007.jpg Projects After sanding off the exterior paper, I began the long smoothing process. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748834626-C2ZMN5XEWU7NOE79K4SR/SJS_0008.jpg Projects Side view. I knew from wearing the regular Judge helmet that the back of the collar hits the edge of the helmet. I raised the back of this design to address the issue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748840690-S7NH2OC5NOKB0TSOX773/SJS_0010.jpg Projects Holding the helmet in strong light, I could see all the imperfections. I marked the low areas with a "-" and the high areas with a "+" https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748845830-ODSWD9UK3WL61W7YEJJN/SJS_0011.jpg Projects One of the clients had access to a super high-resolution 3D printer and sent me a copy of the skull emblem. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748846281-Q7QLNYH8TZ599VCAJJU8/SJS_0012.jpg Projects Test fit of its position. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748851801-H0XDBWGEW7P2YVO3MZ67/SJS_0013.jpg Projects I wanted the crest to merge with the curve of the skull. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748854691-Q52249Z7DOIOG4SONYCK/SJS_0014.jpg Projects I added spikes at the cheek bones to fit into the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748859992-QHDSXXIMOS8UOBWZ618S/SJS_0016.jpg Projects Final helmet with emblem. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748873011-NKUH4XCA3UGDQQGDPV7M/SJS_0017.jpg Projects The skull fit to the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748916124-BKACLZEQH2823RP15EJB/SJS_0030.jpg Projects The first aluminum cold cast resin copy from the mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748920523-H4MCNCNP2HSZPEILAQEC/SJS_0031.jpg Projects I also cold cast the skull. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748920211-DHQDK2OJF5BCHDMMCOF0/SJS_0032.jpg Projects The skull once it was polished. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748934563-YSIK8TSWQBK46D0FAH6D/SJS_0036.jpg Projects The helmet got a base coat of flat black. I also cut a welding face shield for the visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748945799-514GMG4J2R31E7HYUJ9K/SJS_0039.jpg Projects The shield was riveted in place. The rivets were countersunk and the holes were later filled with putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748952782-1UI45HRGKWUF7JX4G2HV/SJS_0040.jpg Projects The rest of the helmet got a gloss black finish. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748951592-XNKOB84GACS2DMV40A4L/SJS_0041.jpg Projects The final helmet as modeled by Judge Rotzler. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748955802-6OL8WH1JN4IO08F6VVTU/SJS_0042.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748959892-UJNK85CRRNLOQN1X133N/SJS_0043.jpg Projects You can raise your head without the helmet shifting against your collar! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748962827-B8YPANN1K6HR3D1ZP74Z/SJS_0044.jpg Projects One of the clients with his custom leather uniform. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523748963452-9MZEZEQ7T7PS519RAEZ4/SJS_0045.jpg Projects It's hard to out-fascist a Mega-City Judge's uniform but I think this does it! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749832196-H4NG5UA7MY72C7JV4SPS/EastMeg_0001.jpg Projects The first appearance of the East-Meg Judges took place in the Luna-1 stories (Progs 50-51) as drawn by Brian Bolland, my favorite Dredd artist. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749830374-HYQA3RIBI058YORB9TDQ/EastMeg_0002.jpg Projects Using every image I could find from the issue, I drew up working plans using my helmet template. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749832547-8CFHQW77LIY8VSZAX0Y4/EastMeg_0003.jpg Projects I imported the paths into Strata3D and constructed a model of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749839989-PMT3683HHLA3N03B2KEF/EastMeg_0004.jpg Projects I imported the model in Pepakura and printed out the paper model. Since the crest needed to be perfectly flat, I cut a piece of 1/4” MDF to use instead of the paper part. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749839977-ZXSRER0W921MIP44OF36/EastMeg_0005.jpg Projects The MDF crest was glued into the paper model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749858002-V5R6AJ5GGCSONNCTXAFW/EastMeg_0007.jpg Projects I slushed Smooth-On SmoothCast 300 into the model, building a 1/8” shell. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749862318-QEY2JVLWO8BKARESC7K7/EastMeg_0008.jpg Projects After sanding off the folds, I applied Bondo to smooth out the geometry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749865594-VUWL1SYSHJR9CMU7BQ86/EastMeg_0009.jpg Projects I cut a hole for the emblem out of the border. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749874585-X1PMRDZLCKLG50669WIB/EastMeg_0010.jpg Projects I cut a puck from 1/4” MDF for the emblem master. I wrapped it in plastic wrap to clean up the hole around the emblem. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749873566-SGYWQ9HF1P9CNYY16R4B/EastMeg_0011.jpg Projects The back of the puck was coated with Bondo to form the base of the hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749880339-SPN74XD2DYDILMLXE3NE/EastMeg_0012.jpg Projects The surface of the puck was sanded smooth to sit flush with the faceplate and match its curve. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749882142-EHE0UYVBJP9JF8K7HLKA/EastMeg_0013.jpg Projects Here is the emblem removed from the faceplate hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749889123-DB51Q2UDUDH534YEFATE/EastMeg_0014.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749892818-68ZCMMVGDN6EEVKRCSOR/EastMeg_0015.jpg Projects I drew and cut out a styrene plastic hammer and sickle and glued it to the emblem (reversed in the comic book universe.) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749901429-HL8QFCNN0Q2016VHBJ5R/EastMeg_0017.jpg Projects The helmet and emblem was painted with a final coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749910223-8KNW4Y1H9JIOI7XGICK0/EastMeg_0018.jpg Projects The primer was wet sanded and polished to a mirror shine in preparation for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749920066-5OU3POJ9EUU6LZCD3ALU/EastMeg_0021.jpg Projects I brushed on a mold using MoldMax Stroke and the resulting roto casting came out of the mold glossy! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749926653-H99P5F3CW0JZD3N1B43U/EastMeg_0022.jpg Projects I cut a piece of Hobart welding shield to fit the faceplate opening. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749926521-VY807IUYWXIQ9AOPUSH2/EastMeg_0023.jpg Projects The visor was secured with pop rivets. The holes were filled with Bondo and sanded smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749935869-ZQ7LB4KMIG2933JPB0UO/EastMeg_0025.jpg Projects The helmet was painted with flat black paint with a glossy red faceplate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749899377-2U1ZITG36RIWAZJFBRUF/EastMeg_0016.jpg Projects I made a mold and cold cast the emblem in brass. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749957533-9B6YMCNY4EGILSSBGZQO/EastMeg_0028.jpg Projects The helmet fits snugly so the interior padding is very thin. I used black headliner fabric and just folded over the edges. The pads were secured with hot glue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749958754-H296LZV5BM88LR3WK472/EastMeg_0029.jpg Projects The final helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749965883-U5CUZBUP520QKQ4BL3P4/EastMeg_0030.jpg Projects Front view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749971680-9XZGHUJ375I66PIW1339/EastMeg_0031.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523749985397-H2WP0USLLQUXH0XWOI27/EastMeg_0034.jpg Projects And worn by my droog Paul (aka Judge Rotzlov) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751075356-I0KY08DZB4TUNMB5BFLA/TS_Snake_0001.jpg Projects I was commissioned to build Robot’s friend Snake. After the complexity of the Robot, I thought that a simple toy like the Snake would be easy. ..what an idiot! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751081281-4L2JIJ6DQ8294EU9GLSP/TS_Snake_0003.jpg Projects One of the clients lent me a Snake toy that was close to the movie version which was very helpful to see how it was constructed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751078960-QSWCIHGXVXEWT24I5GGE/TS_Snake_0004.jpg Projects I built masters for all the parts in Strata3D. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751085925-ETI970CJBMW1NVU1SHEI/TS_Snake_0005.jpg Projects A quick virtual assembly to see how everything fits together. This was helpful to see the range of movement. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751094995-TXQKR1D2ME4QC5379S6B/TS_Snake_0007.jpg Projects I printed out half of each piece so I could make molds. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751099057-ORYS0EPWD15N36KUC7G4/TS_Snake_0008.jpg Projects I made two-part molds for all the pieces. The plan was to cast all the pieces to make a complete kit so that the color would be consistent https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751577985-UQV09F899CDR9YDYM14X/TS_Snake_0012.jpg Projects Smooth-on Task 13 worked the best of the resins I tried but it was nearly impossible to get bubble-free castings with the thin walls. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751660052-2D39Z4QIDTE9DA3V641Z/TS_Snake_0013.jpg Projects To build the segments, I would first have to sand the edge of all the part halves to get a flat glueing surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751133291-TMOGUI0LR18CGE4Z4VGJ/TS_Snake_0014.jpg Projects Without removing the flash (excess plastic from casting), I glued the parts together. This helped to support the fragile arms until the part was complete. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751137578-JPXNWIR479PN2ZIMH7SW/TS_Snake_0015.jpg Projects The seam was puttied up and the surface sanded to remove any other flaws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751139646-KJ89S68VHXY5NQC6P4DB/TS_Snake_0016.jpg Projects I removed the flash and added some Bondo to the inside of the arms to strengthen them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751151678-5J0KFFQQT2GO4I2DAE53/TS_Snake_0017.jpg Projects I then had to drill out any mounting holes that may have clogged up during the putty stage. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751151530-648G5GA3H2RC9YZG3BJI/TS_Snake_0018.jpg Projects A quick test fit. It was a lot of work to clean up the parts just to get to the prototype stage. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751174473-3SHAJ931C71LV5OP7PGO/TS_Snake_0021.jpg Projects I foresaw a grim future of trying to replicate these finicky parts to sell kits. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751184716-3XJSG48U33QARQWG0GJZ/TS_Snake_0024.jpg Projects It was then that Shapeways reduced their pricing significantly. It was now cheap enough to just sell 3D printed parts for the kit, eliminating any need to cast them myself!! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751199875-YNOR9JQQ2PPP1I0BPKTC/TS_Snake_0026.jpg Projects I rebuilt the 3D files to be complete segments. The tail had to be printed as two pieces to allow excess material to be removed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751203112-TYCMGJIMTQL70AAMZWHC/TS_Snake_0027.jpg Projects A little super glue completes the tail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751298375-MN0QOIRWBAYGJFGXSV8J/TS_Snake_0041.jpg Projects To allow the neck and tail to rotate, I built two segments that would lock together and spin. A bit of white grease smoothes the movement. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751310862-TW52YYW5ZGLQK6ZZ5C4H/TS_Snake_0043.jpg Projects The body segments lock together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751344568-YUWLNL5XFFCAF3MTBVKQ/TS_Snake_0051.jpg Projects A coat of filler primer removes most of the print marks. The green plastic make it easier to paint as I don't have to worry about getting color in the recesses. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751349379-TLOLLJDQ5V56X4IX16VY/TS_Snake_0052.jpg Projects I found that Rustoleum "Satin Eden" is a pretty good match for the movie Snake. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751351441-7PJZF8WAS891IC69SFLX/TS_Snake_0053.jpg Projects I trimmed out vinyl decals that I printed at CafePress and wrapped them around each body segment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751357165-FEILQWZ9R20H86AHU6PI/TS_Snake_0054.jpg Projects The rotating neck segment was positioned in the jaw so the holes would line up. A pin slides through both pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751357968-LN2TOMZZ6PZ0ORP12ML8/TS_Snake_0055.jpg Projects The ends of the pin poke out both sides. Since it wasn’t going to show in the completed toy, there was no reason to paint it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751363905-5HL4JVK3BCJBSNMHB8B4/TS_Snake_0056.jpg Projects The pins lock into holes on the inside of the head piece. A spot of superglue secures the head to the jaw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751372513-CAGZDTMJ2I4P1YAAFF3O/TS_Snake_0057.jpg Projects The tongue is secured to the lower jaw with a pin. The slot allow the tongue to dart in and out of the mouth as well as moving side to side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751404091-6ZSF7QD8WHO57YR1LAPH/TS_Snake_0058.jpg Projects Vinyl eyes were trimmed out and applied to the head. When I printed the decals, I made alternate eyes so the expression could be customized. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751411633-MM77O6YBA2XPMZ3EN4KC/TS_Snake_0061.jpg Projects Here is the completed Snake, ready for Andy’s room! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751418223-ZTDACUKECBNFYXKOE0Q8/TS_Snake_0062.jpg Projects Detail of the rattle. In later builds, I added a few pieces of plastic inside so that it would actually rattle! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751418833-PL0FJZITJY0AOCYK8ZPM/TS_Snake_0063.jpg Projects Coiled and ready to strike! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523751423725-5OBSGVLK6XAEXIE4KN5O/TS_Snake_0064.jpg Projects The pivoting tail and neck segments allow for more complex posing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753525639-211XTZL9W8DYDR8WN4JL/Judge0001.jpg Projects Even thought the film wasn’t a box office hit, Dredd 3D had a strong fan following, especially among us prop builders. My friend Paul was also building his uniform at the same time so you’ll see duplicate parts in the working photos (I did not buy two of everything!). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753524117-CFSMBM9E4N8FB5ASH042/Judge0002.jpg Projects Paul and I bought copies of Blue Realm Studios’ Judge helmet replica. This replica is amazingly accurate considering it was produced months before any of the screen-used helmets were auctioned off. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753529269-J5SX02MEN9X8917BPGHE/Judge0003.jpg Projects The first step was to cut away the flash (extra plastic) from the edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753529680-P7LHXQZKTGYQZ6R6N0UK/Judge0004.jpg Projects They also included paper templates for making some final corrections around the face opening. After taping them in place, I used a Sharpie to mark where I needed to cut. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753533348-17GQCBS9JEDZOD3YWVBK/Judge0006.jpg Projects Next I took a palm sander and removed the shield from the forehead. These would be replaced by pieces of Kydex plastic that would form a crisper, more perfect shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753537923-NM5PQ4N9ENIY4ORIDZT7/Judge0008.jpg Projects The new Kydex replacement shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753537677-WZZA95XWVCVC4J36HCPU/Judge0007.jpg Projects I used Bondo to make the edge a more uniform thickness. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753541271-ZFL0MYIVX24E9RIKRF32/Judge0010.jpg Projects The supplied visor was a piece of Shade 3 plastic welding shield. Because it was so thick,it was difficult to securely mount it in the helmet. Eventually, I glued small RC card bolts countersunk from the outside to secure the visor with washers and nuts on the inside https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753542582-9WNQVC9NG5UBPR41NQ1P/Judge0011.jpg Projects After looking at screen shots, I further modified the helmet by rounding the back edge of the trim, thinning the thickness of the border and rounded corners. They are subtle details that nobody else might notice but once I saw them, I had to change the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753093887-WEYBK33L751MEWUVUFES/Judge_0001.jpg Projects Filler primer showed imperfections that I sanded down or corrected with putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753546464-MRK238F7CGLFHI4U4AGN/Judge0012.jpg Projects I applied a base coat of silver so that scuffing would reveal a different color under the paint job. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753549459-NEZC1ZX3FA69UPZ3UK8H/Judge0015.jpg Projects Next layer was the special "Dredd red". https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753094315-QNQYYDHGMD2U5BJOV7VO/Judge_0002.jpg Projects The red areas were masked off so that the gloss black could be painted. The center shown here has already been fine sanded to a smooth surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753096333-HBF6F2V47WN294GAJ8I0/Judge_0003.jpg Projects The black was sanded until smooth. You can see the results in the helmet on the right. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753096739-M0LFIGYCRR9RD6W79TBI/Judge_0004.jpg Projects After achieving a rookie-clean helmet, it was time to weather it. I applied washes of acrylic browns and blacks for a general level of grime, used acrylic silver for edge scuffs and used a rasp for more extreme nicks and damage. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753101456-K7AQ9F5EDQ9KUBHT7PEB/Judge_0005.jpg Projects I made a padded helmet liner by covering 1/4” foam with black headliner material. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753121316-J7Y73CIC9H1YLFHC8ABS/Judge_0015.jpg Projects The jacket, pants and vest were part of a custom run initiated by Kurt Struss for the Judge Dredd Costume Group on Facebook. Based on a screen-used costume, it was reverse-engineered in Pakistan to produce an accurate replica suit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753124391-121FWO9YM5KZ4D3VU4EY/Judge_0016.jpg Projects Even though the pants have Velcro tabs to adjust the waist, I found that the pants work best using suspenders to keep them up. They are all leather thus heavier than normal pants. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753128077-KS7OHA0T7CFPWT53EGZ7/Judge_0017.jpg Projects The knees have velcro in place to secure the knee pads. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753129715-6Y6SB5YNLSSCFEGR5FG8/Judge_0018.jpg Projects Zippers at the cuffs keep the ankles snug. Personally, the metal zipper pulls press into my ankle when worn with the boots so I leave them unzipped. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753132171-KQ055UAOYE937ZZCYSOD/Judge_0019.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753132778-GK1LXOMB9RNN8B6NQ5GH/Judge_0020.jpg Projects I love this jacket! It was the jacket I wore daily until it got too warm. By the time I got the rest of the suit together for conventions, it was well broken in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753139546-33Z7MB5EVYNI3MROUSTK/Judge_0021.jpg Projects The back has thick padding that's completely hidden by the armor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753141785-148J139E4YIN3XU94K2H/Judge_0022.jpg Projects Not only does it have this cool embossed eagle on the right shoulder (which can’t be seen when you’re wearing armor)… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753145467-K5REL9AJZDRS55HGDB73/Judge_0023.jpg Projects …it has Dredd’s badge on the left shoulder. It would be nice to have my name on it, but as it’s unseen as well, no harm done. It matches Dredd’s jacket from the movie. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753148465-3540Z27O9YY77TS62951/Judge_0024.jpg Projects Check out all the cool detail on the sleeve! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753152422-S9GM3AWAGCUPAMAI7E1B/Judge_0025.jpg Projects And to top it off, it has a Justice Department tag inside! How cool is that?! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753152028-X2BXZIGS1SS05DZ4ZYA3/Judge_0026.jpg Projects A British vendor, LeatherNext, also sells a replica suit and armor. I later replaced my leathers for a set of these. There are very minor differences between the two. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753159873-QM61YL4XKSIDZBOH8HGW/Judge_0028.jpg Projects I made the most modifications to the armored vest. I started by re-stitching the amount of border from around the shoulder plates so that it was a narrower, more consistent edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753171096-S0N8A966FGYOOGQBOR86/Judge_0032.jpg Projects The stock vests come with a plastic tab at the base of the shoulder armor that needed to be replaced by an accurate luggage handle (right). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753175386-B7JV6PIZOHGHRUKA8FJ0/Judge_0033.jpg Projects Shortly after, I decided to completely replace the entire piece at the bottom of the shoulder armor. I cut and stitched a new leather piece to replace the vinyl one, added accurate metal grommets and transplanted my accurate tabs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753176681-SABHCGQ83MASWK8OAE1F/Judge_0034.jpg Projects You know, I never thought that I’d be “that guy” who worries about some little detail that very few would even notice or care about….but I guess I am. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753179835-YF7FQ3VCZWA0AHGF0LO1/Judge_0035.jpg Projects These were attached to the base of each shoulder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753191870-6DZXS5LMPV67K509YP2V/Judge_0039.jpg Projects I transplanted new shoulder armor from Studio Creations to the mesh panels of the vest. The replacement armor had better definition and better contour. The gold (on both versions) was painted using Goldfinger-brand “Sovereign Gold”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753187659-JQCMGJBT1I5A774LA0XR/Judge_0037.jpg Projects The other shoulder also got a movie-accurate replacement plate. The new one on the right has much better definition. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753192578-1X9IIH8YJVR1U1BIHE32/Judge_0040.jpg Projects Lastly, I replaced the floppy vinyl belt loops (right) with thicker leather loops. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753248136-8AQOMALHEGX2IUWRTQ1T/Judge_0059.jpg Projects In addition to a Dredd badge that I bought for the collection, I was able to get a custom badge with my name from Sean Cho via the Facebook group!! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753246641-YAV22GP5XFL2ZNVT6UH6/Judge_0060.jpg Projects Of course, being a graphic designer, I was compelled to tweak the “V” to match the blockiness of the other characters. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753251566-AII6PN459IMTMI2G17JJ/Judge_0061.jpg Projects To connect it to the vest, I bought some pin backs which were epoxied into shallow holes that I drilled in the back. I used a paper template to set the pin holes in the chest armor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753251565-V8J3IN5MZ4WNY0X0IGER/Judge_0062.jpg Projects The badge was then weathered and attached to the vest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753255457-B6AEOQGM4MCBNL36G5IF/Judge_0064.jpg Projects I bought my belt from someone on the RPF (Sorry, I don’t remember who). The buckle is cold cast in brass from a screen-used piece and came attached to the belt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753256451-HRB9J1BZIL37RVTFLMPT/Judge_0065.jpg Projects Until I was able to get film accurate replica boots, I bought a pair of Bilt Explorers that were on sale at Cyclegear. They’re a comfortable but cheap motorcycle boot that passes the “close enough” test. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753263236-UB43FO743G5OXY4JRVFL/Judge_0066.jpg Projects After using acrylic paint to cover any of the reflectors and removing a few tags, I attached copies of screen-used shin guards with pop rivets. I cut through the liner to attach the anchors and the ample padding protected me from feeling the rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753263482-O4UB6WD97NSLYVHMOLT8/Judge_0067.jpg Projects I bought copies of screen-used toes cast in a black urethane rubber. I sponged on green paint to make it look like the paint had worn off with use. Both toes were glued to the boots with Loctite 380 glue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753292818-6T5LK8Q0ZMI7IUPNO3GM/Judge_0080.jpg Projects I purchased a pair of LeatherNext’s version 1 gloves which had to be modified for accuracy. I bought some rubber knuckle plates online and glued them to each finger. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753305215-P2GINP7GDQ5WLITTEIDG/Judge_0087.jpg Projects I eventually replaced these with LeatherNext’s v.5 gloves which have the right finger plates, the comm built into the left glove cuff and more accurate styling. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753306039-3CP1SH3M4BQNQ0A144ZT/Judge_0088.jpg Projects The ReelImages suit also came with elbow and knee pads which were made by forming padding over a rigid plastic shell. They came with velcro that matched up to strips on the suit. I wasn’t sure how well that would hold , so I glued some straps inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753310035-RYP3NNCIML6WZB435HGM/Judge_0089.jpg Projects The pads themselves came in black so I had to apply some green acrylic paint to get them to movie spec. The paint out of the tube was pretty bright so I added layers of black wash to tone down the paint and add a visually level of wear and grime. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753310160-1S0VGULA6XVGVGESSMTY/Judge_0090.jpg Projects In anything less than direct light, the color is quite subdued. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753318535-OWRKVXMWFJ7FZSY8T4ZV/Judge_0092.jpg Projects A Judge’s sidearm, the Lawgiver, was purchased as a foam filled, resin casting of a 3D printed model https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753324170-6VBH2Q6W8X7LWRU8ZZ1Z/Judge_0095.jpg Projects Since the gun is build around a Glock pistol, I decided to paint it like one. The polymer frame was painted in a satin black and the parts that would be metal on the real gun, the slide and barrel, were painted with Testor’s Metallizer Gun Metal which buffs to a realistic metal shine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753334242-YP168TI36OTBJN3KFWLH/Judge_0097.jpg Projects I also bought a set of reflective stickers for the selector screen of the gun. Once you throw a camera flash on it, it lights up just like you spent time and money to add electronics! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753334920-Z7GTCTHBYAU0W5GGFN9D/Judge_0098.jpg Projects To connect the front magazine, I countersunk a hole in the base… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753338199-N0YZ5N7NI0S6P6S5YEMN/Judge_0099.jpg Projects …to accept a threaded bolt that would connect to a threaded insert glued into the bottom of the mag well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753347619-CBBVRX7JW0YKWHVLGQU0/Judge_0105.jpg Projects Since the shells are visible in the front magazine, they needed to be painted. The film version looked silver but I opted for a more real world color scheme of brass for the shells and color-coded tips for each type of round. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753349046-6GHON4Y4Y6DDFUN26BIM/Judge_0106.jpg Projects The front magazine loaded with the mounting bolt sitting behind the rounds. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753338335-EMS2HW7TBF7PY7ENVIEO/Judge_0100.jpg Projects In place and secure. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753340651-41ULOXGSM89YRKD7Q153/Judge_0101.jpg Projects I also drilled out the rear sight and glued in a fiber optic shotgun sight. Not movie accurate but I think it’s cool and makes some real-world sense. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753356014-21KT2Z0UHLAD4IS6D9Q0/Judge_0111.jpg Projects The final gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753371009-VH6YVZDHGE22M7KYWM4N/Judge_0121.jpg Projects The model even has Dredd's serial number. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753359694-K59WBX84B05QPEYO02QB/Judge_0113.jpg Projects I used some silver to add some subtle weathering. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753364572-U2NHLV2S3LC6TN699OLG/Judge_0115.jpg Projects Final. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753367083-6EB0G9GR49I7H1G8H04B/Judge_0117.jpg Projects Final. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753364522-SUJGEAPQ85GRY8TT6BT9/Judge_0116.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753373422-DM3XV1ZCPULU4F0HD6Y5/Judge_0123.jpg Projects To make the holster, I bought some .09″ Kydex plastic on eBay. This plastic is widely used for heat formed holsters for real guns and is what they used in the movie as well. I measured the Lawgiver and used MDF to make a master to form around. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753376079-IOTK6TFQKP7R8X2701OA/Judge_0124.jpg Projects Using a heat gun, I bent the Kydex around the MDF to make a three sided piece with lumps to accommodate the sights. The profile was then cut out (oops, you can still see the pencil marks!) and the interior was lined with felt to protect the paint on the gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753376326-PP9V13JF3DHRJD50VYQZ/Judge_0125.jpg Projects A second part was formed and glued into the tip of the holster, holding together two of the sides and keeping the gun from sliding out the bottom. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753379677-9UJ8U74UU54OJFP2KU3L/Judge_0126.jpg Projects I glued and stitched a panel of thick leather to make a belt mounting system for the thigh straps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753379692-JJJ2VS5PI3EGMPTOT35E/Judge_0127.jpg Projects The strap was riveted to the back of the kydex along with a retaining strap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753382230-72MAPGWI8P6DDU9E7YHH/Judge_0128.jpg Projects I attached nylon glides to the strap that attaches it to the belt so that there would be room for adjustment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753382664-1UDTJHU8C22UCO4L32D4/Judge_0129.jpg Projects The final holster. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753384784-84GF0FQ2CI2SK3ZTDGJE/Judge_0130.jpg Projects The movie magazine holders were made from 0.09 Kydex plastic so I used some leftover from the holster build. Working from my plans, I cut wooden blocks to help form the pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753385305-NMV3PG21FEX621XZ221T/Judge_0131.jpg Projects Starting with a piece of Kydex cut to the proper height of the magazine holder, I positioned a piece of wood that I cut to the actual size of the Glock magazine. After heating up the corner with the heat gun, I used another piece of wood to form a clean bend. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753389192-6ROGEW4VXGD5X5BJCZQQ/Judge_0132.jpg Projects I worked around the magazine using blocks to make each bend. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753389416-ZOK7ZEUDNGDQ0WLHMZ4A/Judge_0133.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753393695-6MZM7WS6BTMY4DLZQ484/Judge_0134.jpg Projects One more bend. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753393809-T10XQ7XPDC69U5SNJVGE/Judge_0135.jpg Projects The bottom is bent at the edges to keep the magazine from slipping down too far. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753403330-V8Z7US30BH7WAF0WHIHL/Judge_0140.jpg Projects The part that attaches to the belt was formed in a similar fashion, by carefully heating and folding edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753410708-ZY7LWKFNSJNNITUMJJJK/Judge_0145.jpg Projects Each magazine holder was attached to the base with chicago screws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753414068-LRG6J1DL463GCTDT36FL/Judge_0146.jpg Projects Two magazine pouches are attached. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753414581-CKADMKX036E3AH0IDH4B/Judge_0147.jpg Projects I needed four 19-round Glock magazines but they don’t exactly come cheap! I bought one magazine, inserted a round and molded it. Using Smooth-On Onyx, I made four passable copies with foam cores to save on weight (copy on top). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753417252-0G025FU1JO7NDQ5H0N7W/Judge_0148.jpg Projects The pouches loaded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753418887-PLJJM15CB15OOPQYO79L/Judge_0149.jpg Projects By looking at photos of screen used props and other people’s cuff builds, I built the parts for the zip cuffs and made a mold of them. The cuff mechanism consists of an end cap, the cuff lock box and a cover plate. Here is an Onyx cast resin copy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753422773-GZ07IBKWXKEXUN2AV9OW/Judge_0150.jpg Projects The cuff part was made using 14” black zip ties from Lowes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753424111-GMSFACFXUNGK8AFXBXUW/Judge_0151.jpg Projects Both of the pointed ends were trimmed and glued into the end tab with the serrated side facing inward. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753428108-289QY0EEEW9XGJSZ75PI/Judge_0152.jpg Projects I trimmed off the lock off the other end of the zip tie and threaded it through the mechanism. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753427490-KNVDTUG5V0YAK0C6BWU4/Judge_0153.jpg Projects The ends were then looped around and glued into the top of the mechanism. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753430781-UO5B3UR5L5SGWKRZM3EM/Judge_0154.jpg Projects The cover plate was glued over the mechanism box, locking the ties inside. The loops of the cuff are full adjustable but don’t lock in place. I heated the other end so it could be locked into the side clip without too much tension placed on it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753431293-Q6QSAG5S73NTB5G0138Z/Judge_0155.jpg Projects To make the Stumm (tear gas, in the Dredd universe) gas grenade, I started with a 1” PVC pipe. I chucked it to the lathe and scribed in the horizontal grooves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753435471-T606XQTH7DJL5ZLK7WRV/Judge_0156.jpg Projects I cut off the excess and drilled the holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753435695-JOLQ68EGSSBBXVKBCTI5/Judge_0157.jpg Projects I made the top of the grenade by turning some scrap pine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753440200-8SCKODMMX8SXTI6VY08I/Judge_0158.jpg Projects The top. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753440282-JNNIKEJCJIHW0KHHKI41/Judge_0159.jpg Projects The other end of the grenade was plugged with a piece of MDF. I recessed the cap a bit to mimic what I saw on real gas grenades. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753445394-N1GA7Z3W31QADZSJ131S/Judge_0160.jpg Projects The rest of the detail on top was made with bits of wood and plastic. The tabs that allow the spoon to lock into place were made with a brass rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753446124-RYFMZL4ODDRKVSV96WRK/Judge_0161.jpg Projects The final grenade with a coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753451050-7GIF6ZHQNMWQ80QNEGO2/Judge_0163.jpg Projects To make the spoon, I vacuum formed the rough profile over blocks of wood using scrap ABS plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753453699-ZLSBPZN261RJ77LRMKZ8/Judge_0164.jpg Projects I made a silicone mold and cast a resin copy of the grenade with a foam core. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753459229-5T6KD5X8WBBJT343GXB0/Judge_0166.jpg Projects Spoons and pins attached and a wash of black acrylic to weather them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753462932-UVYTDD27EPEDN27ZCWY5/Judge_0168.jpg Projects I bought these breaching mines from someone on the Judge Dredd Facebook Group. They are copied from screen-used props and cast in hard rubber. They even came with a magnet embedded so you can stick it to a metal door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753464353-G0YBJS0PQQYYI3C6Z786/Judge_0169.jpg Projects I applied a wash of black acrylic to knock down the brightness of the green and dry brushed silver scuffs along the edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753469890-FL5Q1R98J9V37AHUM94R/Judge_0172.jpg Projects Someone online was nice enough to re-construct the backing label on the mine so I just printed it on label stock and applied it to the back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753471713-14XSJ3AOGYEFMX44J9ZX/Judge_0173.jpg Projects While not in the movie, a signature piece of a Judge’s equipment in the comic is his truncheon, or “daystick”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753474384-ZCYAQET5G12KR581OG9Y/Judge_0174.jpg Projects I bought this hard foam training baton online and spray coated it with Plasti-dip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753474598-30MLVMQU8F8HPBS4YNWL/Judge_0175.jpg Projects I also bought this ring holder to hang it from my belt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753480668-WQRP6QOAFETGSNXGO3FG/Judge_0177.jpg Projects To make flash-bang grenades, I found a rubber ball of the right diameter at the dollar store. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753483714-7NMQVV70C1G9F7K6M01Y/Judge_0178.jpg Projects I made a quick mold of half of the ball and cast two copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753484011-UBB3A2ZFC5AW09IOHXBS/Judge_0179.jpg Projects I chucked one half to the lathe and scribed a “button” line. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753487801-TZJJ1CB9UDN7150XBVE6/Judge_0181.jpg Projects Both halves were sanded at the flat side to make room for a inset disk and I cut a space for a indicator light. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753490160-PQRGHX2LS6VU8NWX9P3Y/Judge_0182.jpg Projects Two halves were cast in Onyx resin and glued together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753492459-FMH3PXXZIEXO84JAIT4E/Judge_0184.jpg Projects The grenade was painted olive drab. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753495691-30EQQ4006FWKM2Z6XOAJ/Judge_0185.jpg Projects I cut a small piece of red acrylic for the indicator. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753496504-BNQ6XUTIKRK00WNWBJCY/Judge_0186.jpg Projects A wash of black acrylic finishes the grenade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753502414-8KWU5AWUZUKGLDYGKYS5/Judge_0189.jpg Projects Since I don’t know how to work leather, I commissioned Fevereon to make the leather equipment pouches. One thing I could do was to build the underlying structure of the med pouch. I used the leftover Kydex and heat formed the main box and lower door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753506932-RIWI75TZWXFHE1CA5MC0/Judge_0190.jpg Projects I sent them to Fev and she magically transformed them into a perfect replica! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753506960-EL4K9SWBMAFTZDZ0CCBE/Judge_0191.jpg Projects The inside also had all the elastic loops for the medical equipment (still to come!) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753509816-47RCT6B8MYN37ZFKQDNE/Judge_0192.jpg Projects I applied a wash to add Mega-City grime and to knock down the brightness of the green. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753510852-IK7VTKXC4DWZXDVGT6MQ/Judge_0193.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753512026-HXIXZHXNH5VWL3IKNCQ4/Judge_0194.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753467833-L1P1W5AG8DNUFJMXQ93A/Judge_0171.jpg Projects Fev also made the breaching mine pouch… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753498354-V1ZDTP22H7I09QLKULVL/Judge_0187.jpg Projects …the flash bang pouch,… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753459683-OO4KARM1S2TX16KJLAXC/Judge_0167.jpg Projects Grenade in its belt pouch. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753517424-8NMNR67NG9VYHPDLKSJ6/Judge_0195.jpg Projects I bought a hard rubber copy of a real Boker folding knife from someone on the Facebook group. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753515973-JRN44RXWHLE6GO129NM8/Judge_0196.jpg Projects I painted the case green and weathered it with black acrylic washes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753519128-7XHQR5P76PEPKDBE7FMA/Judge_0197.jpg Projects The final suit in action. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523753520150-3YM08P9MZS4762FTW7G8/Judge_0198.jpg Projects Me and my Lawgiver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834337369-ZYQHNGRUPMPKYYT2MX8W/Stark_Helmet0001.jpg Projects For some reason, I really like the Stark infantry helmet from Game of Thrones. It’s a weird shape and not very fancy but I just dig it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834337121-9CD65HMLYJA7NR2QS0BA/Stark_Helmet0002.jpg Projects I drew up plans based on screen caps… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834338238-67JS07LX9NVLKMYPK6CA/Stark_Helmet0003.jpg Projects …and then pulled the line work into Strata3D to start modeling. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834344653-KPRJTIYJT2GL9LCOZIEF/Stark_Helmet0007.jpg Projects After converting it into a paper model by Pepakura, I printed and assembled it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834348629-U4ZAVFTGKAYRRP5C5JKY/Stark_Helmet0008.jpg Projects I poured Smooth-On Onyx into the model and slushed it around to build up the wall thickness. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834348527-LZJZKS60FNCHXWLZY79L/Stark_Helmet0009.jpg Projects Next I sanded the folds… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834351369-LWE7S7M8ESMYC6OV40IG/Stark_Helmet0010.jpg Projects …and smoothed the outside with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834351798-2H4R4BNTJ27TAR5CA6RX/Stark_Helmet0011.jpg Projects The helmet has a rolled edge but I decided to simulate that with Bondo. I cut a template from styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834355034-QT8YDQ9FMTJNPUT7P7GB/Stark_Helmet0012.jpg Projects I glopped some Bondo and squeegee’d the edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834355118-LPB43VI4YW4YXIVQNHPJ/Stark_Helmet0013.jpg Projects With a little practice, I got a good bead. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834357778-NNST9XZMGCG0GXR1TKCH/Stark_Helmet0014.jpg Projects A little sanding smooths it out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834357982-H5PF1K18KFB7375YK360/Stark_Helmet0015.jpg Projects I measured out the divisions and cut them with a cutting wheel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834360582-TT62JTSPQC2MNWTDHDRJ/Stark_Helmet0016.jpg Projects I brushed on a mold using Smooth-On Stroke. A Plasti-Paste II mother mold, helps it keep its shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834360875-GI6LZXQ7QHSPD6ZTTLFA/Stark_Helmet0017.jpg Projects I mixed aluminum powder into the Onyx and slush cast the helmet. A quick buffing with 000 steel wool make the plastic look like steel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834363594-4ACPCXDD1TSBIOZCTAIP/Stark_Helmet0018.jpg Projects A wash of black acrylic brings out detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834363895-4F8PK9NVH3XU6A4VYNWC/Stark_Helmet0019.jpg Projects Even though the soldiers in the Stark army wore a hoodie to pad and insulate their hemet, I wanted to add padding to finish my replica. I cut flannel pieces to make a quilted liner. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834366746-1DSMGRNCDB11Y7TOH8BL/Stark_Helmet0020.jpg Projects I put cotton batting in between two panels and sewed them up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834367052-OCDVCL4IDV8MWY0C9RJI/Stark_Helmet0021.jpg Projects I sewed the quilting diamond pattern on each panel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834370640-9IWLVROYBHOCL23QTTYC/Stark_Helmet0022.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834373817-24CTGE8GHZKRW3BOYAW5/Stark_Helmet0023.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834375044-IOSEBXZTPNKLHT7NBH3G/Stark_Helmet0024.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834377604-TCETWJQAQM1KSXWJME5M/Stark_Helmet0026.jpg Projects The sides were attached to the center strip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834380235-Z3VP9RYHMTM5O09JF7H5/Stark_Helmet0028.jpg Projects The liner was spot glued inside and I stitched on a leather chin strap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834382761-QUISNTYD1PMIHYPV8V5P/Stark_Helmet0029.jpg Projects Inside makes a nice head cozy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834383271-XXUDQY7Y0T7IF7KEDPAZ/Stark_Helmet0030.jpg Projects Side view https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834385145-BMLORTAQO16FSXVOHZAG/Stark_Helmet0031.jpg Projects The final helmet https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834385465-NI6RP8NQD8HCXVWAV3II/Stark_Helmet0032.jpg Projects Side view https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523834387106-AWSIQ5ELE1UXCS7DM8L7/Stark_Helmet0033.jpg Projects I like a project where every flaw in the casting just makes it look more realistic! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835112094-8Q4SJ72ZWDKAA3I40ZGR/rohan_axe_0001.jpg Projects Ever since I saw this Rohirrim war axe from a Lord of the Rings prop auction, I wanted it. Buying the original was well out of my price range so I built my own. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835113701-LO90OG1K731HVJOG7Z3V/rohan_axe_0002.jpg Projects After drawing up plans based on reference photos, I modeled the horse in 3D and sent it off to Shapeways for printing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835115076-EF0ZC03G47J7A1AYHF9E/rohan_axe_0003.jpg Projects For the blade, I transferred the profile from my plans to two sheets of 3/4” MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835117124-29LZND2MKILVIVBLSXP3/rohan_axe_0004.jpg Projects After glueing them together, I sculpted it on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835120557-J2QG9U1GVS90YH13T9HB/rohan_axe_0005.jpg Projects I had the blade designs laser cut from 1/16” acrylic by Scorpion Ridge Engraving. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835120943-U5WKD9UZYQMHYM5HTS8V/rohan_axe_0006.jpg Projects I used CA (“superglue”) glue to glue the acrylic to each side of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835123940-U2KWHMZKMQBHDUD90QL4/rohan_axe_0008.jpg Projects I used CA (“superglue”) glue to glue the acrylic to each side of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835128549-UIPPGHH2W9DPFPVMJYXU/rohan_axe_0010.jpg Projects The completed axe head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835137031-4H99P2XMH5B378OE6975/rohan_axe_0015.jpg Projects I picked up some 1-1/4” dowels and flattened the sides on the table saw. The flat sides really add to the comfort of the grip and would help prevent the axe twisting in your hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835138397-T7MU1FYTZZLWUE0ELT80/rohan_axe_0016.jpg Projects The other end was tapered with the belt sander to a 1” diameter. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835139662-KDB1GJB4PCLWOEHIZFBE/rohan_axe_0017.jpg Projects A quick test fit of the handle in the axe head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835141505-5UVJRS0OERMUO4QBPKF3/rohan_axe_0018.jpg Projects The handle inserted into the axe head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835143742-GLACXP4XT1D42OK8OD0W/rohan_axe_0020.jpg Projects After drawing up plans based on reference photos, I modeled the horse in 3D and sent it off to Shapeways for printing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835148953-0RD5VW88TF41652PPV4Y/rohan_axe_0021.jpg Projects A couple of weeks later I got the 3D print of it. I could’ve made some of the detail deeper but it’ll still work. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835149102-AQ42DUI183S1DEL570M5/rohan_axe_0022.jpg Projects Glueing the horse in place was the final step before molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835152259-QW50OHWV0IN6A8YDVLNF/rohan_axe_0023.jpg Projects I inserted an aluminum rod and poured silicone into the handle hole. The rod will help with registration of the mold parts and make it easier to remove the plug from castings. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835152720-SXJ7UIVDWEWABOQUS86H/rohan_axe_0024.jpg Projects Once the plug cured, I prepped the master for a two-part mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835155921-VJ2QF5W56BNA6ODQ90K0/rohan_axe_0025.jpg Projects I mixed up a small amount of aluminum powder and Onyx resin to capture the detail in the new mold sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835156463-GESKGB0YX13D10FIIYXW/rohan_axe_0026.jpg Projects The raw casting looks dull grey but after wiping it with acetone, buffing it with 000 steel wool and burnishing it with swirl remover, it shines up like real metal! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835160686-DLL1QJL7OBX8CBOMSVKR/rohan_axe_0027.jpg Projects I painted the detail with black acrylic and left it to dry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835160892-9U3H734T6WZDJ5ETBPP1/rohan_axe_0028.jpg Projects A quick scrubbing with steel wool removes the surface paint but leaves it in the low areas, bringing out the detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835164417-CUV01846F4D4KC6WQENX/rohan_axe_0029.jpg Projects Next I knicked the blade with a knife and scuffed it with an emery board to simulate battle damage. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835164184-9T7YLNJ8Y6NV1WTO66NW/rohan_axe_0030.jpg Projects One little detail I needed to add was the metal wedge that’s embedded into the end of the handle that keep the axe head from flying off. I cut scrap aluminum pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835169722-LI7IZTNNV8UXX2S89OML/rohan_axe_0031.jpg Projects A quick trip to the belt sander turned them into rough wedges. Since they’re only cosmetic, they didn’t need to be very deep. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835169527-A1DILTCDLQR42FD4WWWG/rohan_axe_0032.jpg Projects I didn’t want to stress the plastic of the head by hammering in the wedge, so I cut a shallow hole in the top of the handle with a rarely-used Dremel cutter. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835172925-Z0SOXKP5D8NYW7VUT9PF/rohan_axe_0034.jpg Projects The wedge tapped into place (no glue needed) and some more weathering to blend it in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835177103-GYMMP0M9GK4KE2CATJ4J/rohan_axe_0035.jpg Projects The last step was to wrap the handle with a thin strip of leather. This, too, was weathered with a wash of paint…because of battle dirt and orc blood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835176981-IPIANN5R5WFK5OPILC9V/rohan_axe_0036.jpg Projects The completed axe! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835183298-0RY5QOX1YTWI9GCORT6D/rohan_axe_0039.jpg Projects Detail of the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835183883-EKPX79DPSRXZ6OGJ65HB/rohan_axe_0040.jpg Projects Blade detail https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835186378-A35LY4RQFB76MW4FTY54/rohan_axe_0041.jpg Projects Horsie detail. I think this would really hurt! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835993206-GEY4KZFJC1T8HWIVD5FW/Dredd0001.jpg Projects After building a kit of the Dredd 2012 Judge’s helmet, I started thinking back to that original helmet. I modeled the lid in 3D, and ran it through Pepakura to make a paper model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835993012-XDNP3VOKZU3J5XCMN85E/Dredd0002.jpg Projects I tried to be clever by printing out one side, placing an extra sheet under the print and cutting both sides out at the same time. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835995375-7NN232AYZUGIA1JOLKGQ/Dredd0003.jpg Projects The result turned a little hinky since the left side didn’t have any guides. I would pay for being lazy! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835995473-S2J2MG41EVGU6G8DNJK8/Dredd0004.jpg Projects I proceeded to slush Smooth-Cast 300 resin into the paper model, eventually building up a thick wall. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835998265-U68POOGDYBKLYTV7YFPI/Dredd0005.jpg Projects After sanding off the folds of the paper, I added Bondo to smooth out the contours. Because of my lousy paper model build, I had to do a lot of corrections to the geometry of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523835998369-L138WQZFTWWZ710KTFQK/Dredd0006.jpg Projects Another dumb decision was to build a raised border into the model. This detail would be easier to add later with Bondo, especially since I wanted to keep it very shallow. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836006897-2040MZ1FIHM8RFY55PWP/Dredd0011.jpg Projects The nose pieces turned out asymmetrical so I cut them off and realigned them in the proper angle and position. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836006913-YH4LSSWAJ1JP4QPDXYVJ/Dredd0012.jpg Projects Steel pins kept them in place while the glue set. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836009489-T5RQX1U361XRNCHNP6HC/Dredd0014.jpg Projects I heat formed a piece of Sintra to become the center shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836012684-6ZLPEIU6H6GBJKKSBGFN/Dredd0015.jpg Projects I cut some channels into the Sintra and smoothed out the finish with gloss paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836012599-LA74N79ZZQTM6T178V69/Dredd0016.jpg Projects The final helmet with black primer. It’s kind of an interesting look… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836015466-I9KUKALP0CYWHPQZI9XN/Dredd0017.jpg Projects I put it on my plaster head and inserted a piece of poster board for a stand-in visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836015568-Y4TOHF1OBLAPJ38Y78BO/Dredd0018.jpg Projects I used MoldMax Stroke to build up a thick silicone mold. This was eventually covered with a Plasti-Paste II mother mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836018685-2Z9YEQPMM0K8TUMPDKY5/Dredd0019.jpg Projects The shield was molded separately so I could cold cast it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836020904-4KGDQK07N77EDDJJH2AI/Dredd0021.jpg Projects I rotocast the helmet with SmoothCast 300. The shield was cold cast with 300 and brass powder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836025714-M53BCFRBHFSVO1S5TJWG/Dredd0025.jpg Projects I had some leftover .06 PETG plastic from my Toy Story Robot build, so I heated it up in the toaster oven and draped it over a plastic bucket to form the visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836025988-IJ6IS53P4Q6MBKVY1QVL/Dredd0026.jpg Projects I painted the helmet with a flat black spray paint and then masked it to paint the red border. Once that dried, I wet sanded the finish and then gave it an enamel clear coat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836028344-3T3HZL10LWZBJD2LHOZW/Dredd0027.jpg Projects The visor was positioned and then held in place with a clamp. I then ran a bead of hot glue along the inside of the visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836028641-Q4DJO881K0PV9D8NS1OK/Dredd0028.jpg Projects I picked up some limo window tint from the auto parts store and ran a strip across the inside top of the visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836030834-4LHHVGUUCEEF40G74KRB/Dredd0029.jpg Projects The comic version of the helmet is much smaller than the new movie version so there wasn’t much room for padding. I opted to line the inside with black felt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836031711-5J45COOTQJKAU766ME9W/Dredd0030.jpg Projects So the helmet is held in place when worn, I made some pads from 1/4” upholstery foam and black headline material. These were placed above the visor at both temples. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836032700-MY9XRBXMMKW3BTCV5K6M/Dredd0031.jpg Projects The final helmet worn by me. My 16-year-old self can now rest easy. We gots our helmet, buddy! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836035344-XRA3IUJMXXA1BE8GPIN5/Dredd0034.jpg Projects Front view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836036129-T88GI7WPP8IP6T9BMXQT/Dredd0035.jpg Projects 3/4 view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836037386-95DDENVGIQM5XY86ROJP/Dredd0036.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836037969-4MOA7ZQQK0HMKSXCTGQI/Dredd0037.jpg Projects Detail of the polished shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836883750-4NK7YJG18ZYWTFQCTOIB/UrukGeneral_0001.jpg Projects At some point I noticed that the Uruk-Hai General’s helm has, as its base, the Berserker’s helmet. With a little modification I could have a new Orc helmet! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836884253-F41NETFNS3F28NX3WNY2/UrukGeneral_0002.jpg Projects I made a mold of my Berserker helmet and slush cast a resin copy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836886213-LEYXLPY1HPJYZJMGE8PX/UrukGeneral_0003.jpg Projects I cut a crest from thick (0.125″) styrene that fit over the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836886747-YPAW53259P7HLF8C0U1C/UrukGeneral_0004.jpg Projects To get a forged look, I softened spots with a heat gun and then pressed pits into the surface with a rough grit sanding sponge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836890161-UXAKA7O4J7DP7PQT608T/UrukGeneral_0005.jpg Projects I glued the flat side of the cast resin brackets I made (heat bent styrene and cast resin “rivets”) but the other side wasn’t sitting flush with the helmet’s surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836892878-Y86G68YS05WX7NT4N19C/UrukGeneral_0006.jpg Projects I softened one side of the bracket with a heat gun… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836893501-VXAPWBKEYIZMFP6HWFZR/UrukGeneral_0007.jpg Projects and then pressed it flat until it cooled. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836897076-U6LBBVNLIERQ53F0HUAG/UrukGeneral_0008.jpg Projects The General’s helmet has round, piggy eye holes so I needed to make inserts to convert the eyes. I heat formed some thick styrene and pressed it into each hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836897324-0J60KSVICS3Q7A5PLS6E/UrukGeneral_0009.jpg Projects I applied mold release to the old eye holes and then glopped Bondo into the hole to fill the space. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836900044-PM4MXJ43WAHCQ5LXESUP/UrukGeneral_0010.jpg Projects The Bondo was sanded flush… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836900044-IAHTQ8RS2G5I70OU7OXB/UrukGeneral_0011.jpg Projects …and new eye holes were drilled in the insert. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836904171-FJCZLHW4JRTDPHP5O4DM/UrukGeneral_0013.jpg Projects I made a mold of both inserts and cast resin copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836906429-SKNCWEO3JKRNAN3E4CD0/UrukGeneral_0015.jpg Projects I made a mold of both inserts and cast resin copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836907722-9BEI4JOF3XKHBDX5XWTQ/UrukGeneral_0016.jpg Projects After glueing on some extra rivets across the forehead, I gave the helmet a base coat of Rustoleum Hammered Silver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836909530-ZO82GDAA436HCRZT1LPI/UrukGeneral_0017.jpg Projects A wash of black acrylic paint knocks back the shine, brings out detail and makes it much more realistic looking. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836915231-ENKYVHC0DGJBOVOUGDDL/UrukGeneral_0021.jpg Projects To make cheek guards, I cut thick styrene and heat formed it to fit snugly against the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836915638-1XIN4SIAW391IYQHDJWL/UrukGeneral_0022.jpg Projects I made a mold of these pieces and then cast resin copies for the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836917744-CRIAHRLHJ0UVNSL62YJ8/UrukGeneral_0023.jpg Projects These were painted, weathered and then glued on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836920398-KAXSMEVAPBKVUDHPCZNQ/UrukGeneral_0025.jpg Projects I added acrylic “rust” to areas that would collect water or parts where water might drip from. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836918758-0GQO7QCRGVCR56QPUPI5/UrukGeneral_0024.jpg Projects I had a thin area in the casting that I turned into a rusted-through spot rather than patching it with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836921482-VCYKVMYZSOPQA7X8U2DF/UrukGeneral_0026.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836924824-38CD1WPK2JD6DVMMP621/UrukGeneral_0028.jpg Projects The final helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836927238-6MBT2HP0IHXGXB19XHVI/UrukGeneral_0029.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836928224-YNHIAMC4IPG53MSHRZPX/UrukGeneral_0030.jpg Projects Back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836929793-AT8APCKELK5PUAW1NFYX/UrukGeneral_0031.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836924028-DSABFT4CIIT4JWIRC2K7/UrukGeneral_0027.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836931250-SM0HPHWSEFC9XAW84HLI/UrukGeneral_0032.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523836932450-SN3FP84A2IBSUXMYY9CL/UrukGeneral_0033.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/99d13b64-941e-4775-8f03-961c604aa685/thumbnail_IMG_7967.jpg Projects - Make it stand out Since this post, I have re-created the head, jaw, neck, chest and base to print in PLA. They are now more accurate and, best of all, easy to paint with zero masking! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943732439-R5DB7SM3U1BQKOW3H4J8/TSrobot0001.jpg Projects After building Mr. Spell, I was commissioned by the same group of rabid Toy Story fans to build Andy’s Robot, shown here hanging out with his friend Snake. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943732075-N4NN7NX1BWA4073MZZDD/TSrobot0002.jpg Projects Working from screen captures and basing the size to be in scale with Mr. Spell, I drew plans to work from. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943736209-730F5W9JTV4VNZA4Y8KA/TSrobot0003.jpg Projects I started by cutting the profile for the “hips” out of basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943736300-WY9B3Y03MVUHHCSPRGSN/TSrobot0004.jpg Projects I replicated the shape twice more and glued the pieces together to make the proper width. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943740405-3OCQR41AEWN9XQ0ETSY6/TSrobot0005.jpg Projects I sanded down MDF to make the domed piece that connects the hips to the torso. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943740398-DXL5K4TY6LSPKAOWKER3/TSrobot0006.jpg Projects I flattened the top of the dome to glue it to the hips and then used Bondo to complete the corners. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943745100-1AB644475T2VLRAENQ2H/TSrobot0007.jpg Projects Lastly, I drilled a guide hole in the center of the dome for the torso to pivot on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943745369-3WKE90NXHZDRM2O6ZNLG/TSrobot0008.jpg Projects The claw base was cut from a piece of basswood. The forearm master was a brass tube of the proper diameter and I found a reject resin gem that I could use for the hand rivet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943751501-HAKBHU5DMY9D2EE4XHH8/TSrobot0009.jpg Projects Using a circle template to mark the diameter I needed from the dome, I made a rough cut. I then sanded the base to get the dome to the right width. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943751317-3YFOJ17NHNHTZC59FS8V/TSrobot0010.jpg Projects The domes were glued in place and Bondo applied to round out the space between them. The end of the forearm tube was cut to fit that curve. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943758469-KK9AMFIRVIJZGC60BM5K/TSrobot0011.jpg Projects I filled the ends of the forearm tube with Bondo and then drilled a hole in both ends to fit acrylic pegs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943758469-QDKAQTZFO20HAM3LXGL9/TSrobot0012.jpg Projects The other end was fitted with a styrene washer that fit the inside of a 1/2” copper pipe (which will serve as the upper arms). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943763993-14M70H3IYKXOHY0HRG5R/TSrobot0013.jpg Projects I drilled a hole in the base of the claw for the forearm peg. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943764544-5YP55RS332OWLTR06U6U/TSrobot0014.jpg Projects A quick test fit to make sure everything is ok. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943768793-V9LFEP9PPLDY3C7F1WG5/TSrobot0015.jpg Projects Since the upper arm inner diameter is much wider than the forearm tube I needed to make an angled transition piece. This would act as a stop to prevent the forearm from pulling out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943770244-C7E3VOQD4L6WSTOW049M/TSrobot0016.jpg Projects After chucking it to my hand drill, I used a chisel as a “poor man’s lathe” to shape the piece. Here I’ve just cut the parts that inserts into the upper arm pipe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943774383-46B5V53NC088IM163HXU/TSrobot0017.jpg Projects A bit more work angles the exposed sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943774668-SVJEHMNIAQYCY4JB46DQ/TSrobot0018.jpg Projects The part is inserted into the pipe and drilled out to allow the forearm tube to fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943778087-S72PN43VQ3QA8AH1Y19P/TSrobot0019.jpg Projects To make the rotating shoulder ball joint, I fished another spare resin gem out of the scrap box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943778728-ZGXISZLGC0VZ1RELJAUA/TSrobot0020.jpg Projects I drilled a hole for the upper arm pipe and cut a piece of styrene for the collar at the joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943781867-H7AIBVW1ERV06TW920O1/TSrobot0021.jpg Projects All the parts assembled! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943782159-NHENKDZL1U9FFDAOV0WV/TSrobot0022.jpg Projects And the claw retracts as planned! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943785663-773N36P1T8N7B5QBH92X/TSrobot0023.jpg Projects On to the torso, I cut two pieces of basswood to make the battery door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943786323-LVKN8DTAERU4YZ8768LL/TSrobot0024.jpg Projects The torso would be molded in two parts so I cut two blocks of basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943788644-71146Q7VJIMUPU77HEAX/TSrobot0025.jpg Projects I marked the circular base and then cut and sanded the bevels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943788837-A3GM8O2UIBO9EP6SMT3R/TSrobot0026.jpg Projects I cut a piece of basswood to make the chest shield and sand an angle to the back so it sits properly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943792541-HQI7YUJDRRU82TOLC4IR/TSrobot0027.jpg Projects To make the rounded border of the arm holes, I cut two rings from 1/4” MDF and rounded the edges on a makeshift Dremel router “table” . Please don’t do this. It is very dangerous. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943794149-B7LKZ7AJGZW0SO1W0LK0/TSrobot0028.jpg Projects Before and after, with no blood spilled. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943797956-HS1EQBHRK0G1RPR5F11S/TSrobot0029.jpg Projects A test fit of the shoulder joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943799407-XOP4LYQLUHVSKQHAIN54/TSrobot0030.jpg Projects The rings glued on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943802419-JZ28P4EXWSCNMLUYFKYW/TSrobot0031.jpg Projects With the arm borders glued, I used Bondo to fill in the space between the chest plate and the torso. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943805439-1U1XKSAQDNJ7M90650CM/TSrobot0032.jpg Projects To make the jaw, I cut a piece of MDF and sanded the curved base shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943808551-593GBKVE9IJR8SHZLMYD/TSrobot0033.jpg Projects After rounding the corners and front, I continued to sand the jaw to its organic shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943809131-61CZTLULBH8Y2DV03PWL/TSrobot0034.jpg Projects I chucked a router bit in my drill press and cut a hole in the bottom of the jaw for the neck. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943813480-2L9JAGQTBQGQXH9I3GNJ/TSrobot0035.jpg Projects A PVC pipe is cut and glued into the hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943813987-8FB025AZQ183EC9UDRCQ/TSrobot0036.jpg Projects I cut out a slot in the jaw to hold 12 acrylic dome “teeth”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943818818-5K55W7N12FU0KYXY3JTZ/TSrobot0037.jpg Projects The head started with a thick styrene base supporting basswood back and sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943819123-ZNIYGRBH0TD3EOITZ1HS/TSrobot0038.jpg Projects The interior of the head will be covered by a clear dome so I cut a piece of basswood to fit within. I sanded the head pieces together so that they became one smooth shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943823592-TQPNI2Z8HCXQWTX3DPC8/TSrobot0039.jpg Projects I vacuum formed some styrene over the interior head form to make a stand-in visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943823709-UAT4GLJG2KSP3JQJ2U95/TSrobot0040.jpg Projects I cut some styrene panels that fit inside the head to act as a shelf for the visor to rest on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943827912-ELSV5DV9MQWKDBOHCADU/TSrobot0041.jpg Projects A quick test of the theory. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943828558-EBX4JJCP2ZX9NDMRYHKE/TSrobot0042.jpg Projects The handle was cut from a piece of 3/4” MDF and sanded to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943831544-SBDS1A1ZNAUFE94IP863/TSrobot0043.jpg Projects Mr. Spell’s ear pucks are slightly bigger than what I needed for the Robot so I cut down resin castings to the right size. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943832476-IMF0CW6LX396OUCF0WE3/TSrobot0044.jpg Projects The new pucks were glued to the base of the handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943834843-K3NM1U7FJ01GZF2FRR1V/TSrobot0045.jpg Projects I cut holes for the ear pucks in the side of the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943835650-ED6TKCAJRECF4W27OSOT/TSrobot0046.jpg Projects A quick test fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943837964-9RHABISEY3WO041E4SSL/TSrobot0047.jpg Projects Back on the hips, I drilled holes to fit the stainless steel axles. Bondo was added to true up their alignment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943839611-T223F4LFE9ME5KNIZVIT/TSrobot0048.jpg Projects I cast a plug of resin for each size wheel, then drilled out each side with forstner bits to make hollow wheel rims with a flat wall in the middle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943840783-F8CW65K9CE0K2NR3ESBS/TSrobot0049.jpg Projects I cast two more resin plugs and lathed the “hub caps”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943843965-J5DD18L9NHDFCJNIQ5EE/TSrobot0051.jpg Projects The hub caps slid right in and glued the center. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943845446-YN6K8A80RRN7SQ7G5P3I/TSrobot0052.jpg Projects The other side was drilled to accept a styrene tube that fit the axles perfectly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943846739-0ZDELBZIEAGLZFPSFBD5/TSrobot0053.jpg Projects I sanded MDF blocks to make vacuum forming masters for the brains. The hole will hold the stalk of the eye. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943848517-RTAJS484PIW5JNGK419T/TSrobot0054.jpg Projects A quick test to see whether I would use clear or thin styrene. I found that .015 white styrene allowed the inner lights to show but was thick enough to support the eyes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943849525-Q0HMU5J5WKLY6NQ44E9R/TSrobot0055.jpg Projects I cut and sanded a MDF master for the mouth shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943851498-R0GAWVFV8SHR02YMY0UH/TSrobot0056.jpg Projects I made resin copies of the wheels and fit them onto the axles. It rolls nicely! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943852451-34K6UXM4WV5SMUHC379F/TSrobot0057.jpg Projects Using a length of fun foam, I could get an accurate length for the tread. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943856623-LJG9MSL7TQKG2LXOBA8O/TSrobot0058.jpg Projects I cut balsa wood to the right length, notching each end to overlap for a glue joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943857073-TB7RXEBR7P7PL2I6GJXO/TSrobot0059.jpg Projects I had the letters for the tread laser but from 1/4” MDF by Scorpion Ridge Engraving. The unused parts made a nice template for glueing the letters and numbers down to the base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943861114-JTP4ZTPLF5KE8XVAZKVD/TSrobot0060.jpg Projects The completed tread masters. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943861113-7YK5XZH31XEWSL24ICVR/TSrobot0061.jpg Projects Looking at the reference pictures, I noticed that the letters were too thick. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943864312-0B6XMUZ4U16GC9KAIOHI/TSrobot0062.jpg Projects A trip to the belt sander brought the characters down to the right level. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943864313-O1E18LE0ORXOYZKDW9EX/TSrobot0063.jpg Projects With the tracks finished, I made a mold for production. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943871195-K6X25FR91ZQCXIDP54FK/TSrobot0064.jpg Projects To connect the body parts, I decided to use pieces of a lamp nipple (a brass tube with a treaded exterior.) I drilled a hole in the hips to accept the hardware. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943871287-LBSMQ0R4TESKE1TE0C29/TSrobot0065.jpg Projects I drilled a hole under each brain dome that would connect up with a larger hole in the jaw. The lamp nipple allows the wires to pass into the torso and allows the head to fully rotate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943874743-WTSLFU13HYWX2FT35YG1/TSrobot0066.jpg Projects I made an inner sleeve on top of the torso that the neck tube would fit over. The connecting lamp nipple passes thought the center. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943874742-S4C09UX94Y9QTJP3EM9Z/TSrobot0067.jpg Projects I had the battery symbol laser cut from 1/16” acrylic and glued it to the battery door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943878907-5E0X15750EZYAA7PQR1W/TSrobot0068.jpg Projects I cut a slot for the electronics switch into the battery door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943879149-LLBUFXMNV152CG5PYOSA/TSrobot0069.jpg Projects The switch lever sticks out of the hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943883111-QD9PI0SAGP040DQJ9VWT/TSrobot0070.jpg Projects Tiny, tiny “ON” letters were laser cut from acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943882529-PDS4HSHYK9VY1DF0HQFQ/TSrobot0071.jpg Projects These were glued into the recessed slot, low enough to pass under a switch cover. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943885780-S812EPZUUL67U6DO9OQH/TSrobot0072.jpg Projects A switch cover was made from MDF and glued over the electronics switch lever. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943888464-Q6W0YQA3U922NA0I771Z/TSrobot0073.jpg Projects The eyes were made with MDF disks glued to wooden dowels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943889488-N61MDJYX3I536XJFXVUN/TSrobot0074.jpg Projects I made silicone molds of all the parts. It took a gallon of Smooth-On MoldMax 30 to mold all the parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943890965-I5GH8272L4WAE3XQHUVN/TSrobot0075.jpg Projects Resin castings for the initial four Robots. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943893630-0ETA1RIKIV8RDCC22P8H/TSrobot0076.jpg Projects I cut out the arm holes in the torso and removed excess resin inside so the arms would rotate freely. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943895102-TWYKAHSDYKGBDX188502/TSrobot0077.jpg Projects To form the arm socket cover, I made a Bondo casting of another gem the same size as the shoulder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943898737-82GXGYBVY0ZLHNLHGMB4/TSrobot0078.jpg Projects This piece was smoothed and molded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943899080-RHLSB5FXUCXOXKWZZTKE/TSrobot0079.jpg Projects A resin copy of the shoulder bracket from the mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943901578-FL10K8519CWOPN41BKIN/TSrobot0080.jpg Projects A resin copy was placed behind the shoulder in the torso cavity and hot glued. The glue has some flex to it allowing the shoulder to move while being held snugly in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943903100-39DHFSKPC7KY3U8Y4VUO/TSrobot0081.jpg Projects I cut segments of 1/2” copper pipe for the upper arms. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943906625-XXPESKXXX92QR3DZKQXN/TSrobot0082.jpg Projects The “elbows” are then glued into the copper pipes and the forearms tested to make sure they slide smoothly. The forearms were later painted with a gloss white paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943908200-70ZR7C6HMMWKUBGCU6LB/TSrobot0083.jpg Projects The forearms (unpainted since they needed to slide) were inserted in the upper arms and glued to the claws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943910242-7XJ2WQ3RMRWKIZ3A4PG5/TSrobot0084.jpg Projects To cast the tread, I mixed up a small amount of Dragon Skin silicone and added red Sil-Pig pigment. This was laboriously dripped into the letters. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943911689-0DSEY3WJVHJISTTVUREM/TSrobot0085.jpg Projects I then mixed up a larger amount, tinted it with grey (white for opacity then black for color) and then covered over the red letters after they had cured. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943914039-II7SLQ1875SZXX1Y0W7R/TSrobot0086.jpg Projects In a few hours, I could peel out two rubber treads. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943915159-4BD6YL9N3SOG3YA28Q6S/TSrobot0087.jpg Projects The ends were cleaned with acetone to remove any oils or mold release and then glued together with Sil-Poxy, a glue made for silicone. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943917457-JIBJPW0AQLTBKBN3C2QV/TSrobot0088.jpg Projects I cast the eyes in red tinted clear resin so they could be illuminated. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943919477-RNQ3V3XO03TFLICC3XQR/TSrobot0089.jpg Projects I made Bondo anchors (which will be molded and cast) that could be glued to the inside of the brain to hold the eyes https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943919940-O8GK0Y7QLEYY9CEQZ2GA/TSrobot0090.jpg Projects I cast the anchors in clear resin to minimize any shadow they might cast in the brain. The eyes were inserted into the brain and into the hole of the anchor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943924087-1WPMHX6AS8Y9HK0NT8RB/TSrobot0091.jpg Projects I vacuum formed clear PETG plastic for the mouth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943924132-VEO6438AKZA1D0YLLIH3/TSrobot0092.jpg Projects I purchased red acrylic cabochons for the teeth. They have a silver backing that really reflects the light. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943925909-BAE1GNQ8AXTEX0VFFMLC/TSrobot0093.jpg Projects Twelve cabochons were glued into the mouth. The ends had to be notched to allow the mouth shield to slide by. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943929330-ZCEZ324PS29RPAN4WP6V/TSrobot0094.jpg Projects The mouth shield was carefully trimmed to fit and was glued into place with Testors Clear Parts Cement, which will not haze clear plastics. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943978055-WLTU7BV4UTX4L1Q675C8/TSrobot0121.jpg Projects Randy at VooDooFX made the electronics for this kit. It features two red LEDs to make the eye glow and a bank of LEDs for each lobe of the brain which will pulse different colors. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943931249-02QJ83KSY5JHMPVVMIPV/TSrobot0096.jpg Projects Randy was also nice enough to include plastic diffusion material so no “hot spots’ would be projected onto the brain. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943929911-J6R1NJTGYEJC858474EX/TSrobot0095.jpg Projects To make domes that would fit over the light banks, I made a block and frame from MDF to form the plastic over. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943933858-VXX3GR2IKCVLVSLHZY5U/TSrobot0097.jpg Projects I heated the diffusion material, placed it on the block and used the frame to squish it into shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943934451-WJY1X6F3R295YO1J99BI/TSrobot0098.jpg Projects The formed and trimmed diffusion dome. It’s not pretty but it will do the trick. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943938567-2L7UK0OVQEC1WYWX5W1H/TSrobot0100.jpg Projects The diffusion domes were glued over the LED banks and the eye lights were hot glued so they lined up behind the eyes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943941893-49LUBS2JRI97AK6DFMP7/TSrobot0101.jpg Projects The torso was secured to the base with a nut over the lamp nipple. A spot of glue locks the nut and allows the torso to rotate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943946986-46CL97WUIGTUAT0MCS53/TSrobot0104.jpg Projects After painting, the neck was too tight in the torso to rotate freely. I sanded off the paint and a bit of resin for a looser joint. A bit of lubricant helps as well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943950596-56LSQYPTXSOP6FW936LE/TSrobot0105.jpg Projects I cut the wires of the electronics and fed them through the neck hole. Inside the torso, I re-soldered them to the switch and power supply. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943958444-FEYRV3HOUUQ000DMWRLY/TSrobot0109.jpg Projects The brains could now be glued over the lights. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943979882-ZO75U72XC2O99GAVM530/TSrobot0123.jpg Projects The eye anchors glued inside the brain shells. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943958800-2EEPML9NAE63RM8XE6OU/TSrobot0110.jpg Projects Eyes and brains glued into place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943968822-ODCIOGT0VYA63ZZ7UMVY/TSrobot0115.jpg Projects Eyes and brains lit up. Check out the lights in action here. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943961850-3VU0Q1AT82IVXO0V8R0J/TSrobot0112.jpg Projects I vacuum formed clear PETG to make the head visor, trimmed it and glued it in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943980702-8D6V3S1R2B1K473TUUXR/TSrobot0124.jpg Projects The finished Robot! See a video demo here. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943982694-5YOJ6HDUG8E872C0O1DG/TSrobot0125.jpg Projects The finished Robot. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943983079-4PURRVAVW9AEE0TAXR5U/TSrobot0126.jpg Projects Back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943985697-NWLWVVK3IW9OCIQ0PA5Y/TSrobot0127.jpg Projects Arms extended. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943990544-G3NVPQOUCYK75ODK0H22/TSrobot0129.jpg Projects Tread detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943990552-28FL18DQAJC7YYCY1C6X/TSrobot0130.jpg Projects Face detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1523943992655-JD9T9HFN6KY7F17XP03S/TSrobot0131.jpg Projects Back detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290174424-OQXUDIU9A0NBYXFUTN4I/MrSpell0001.jpg Projects I was commissioned by a Toy Story collector in France to make a replica of Mr. Spell. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290171593-84O588ZR79XNNT8YTR7W/MrSpell0002.jpg Projects After drawing up plans, I started by cutting layer of MDF to make the thickness of the toy. Each side was made with a layer of 3/4″ MDF and a layer of 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290177571-ASNQYKLURK66JJ4T3B8S/MrSpell0005.jpg Projects I glued the 3/4″ and 1/4″ pieces together to make two halves. Clamping both sides allowed me to sand the edges to make the fit perfect. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290181287-VW71UD3Q7UVCS9TEQ7PM/MrSpell0006.jpg Projects I used the belt sander to taper the body halves (narrower on top) and then rounded the front and back edges with a 1/2″ router bit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290174984-Y1ULGUNHM8OT3NYUR9U9/MrSpell0004.jpg Projects I then cut the handle from a single piece of 1.2″ MDF and rounded the edges with a 1/4″ router bit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290181033-FFRK316F4TSBFUJ1ZOPW/MrSpell0007.jpg Projects I cut slots on both sides of the body to fit the handle. Mr. Spell also has a recessed seam between the two body halves which I made by cutting a 1/8″ acrylic layer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290184097-92UK5PUWKUADSSZ18FGU/MrSpell0009.jpg Projects A quick test fit before I sealed the MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290183379-ZX3D4SP4M3UDY5RKTK7H/MrSpell0010.jpg Projects There’s nothing like a coat of primer to show you how much you have to fix! A layer of spot filler putty smooths out the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290187663-3DF2ZJMRNHSYXULVOC4Y/MrSpell0011.jpg Projects To make the engraved name plate on the handle, I had the letters cut into 1/8″ acrylic panels and glued them to both sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290193598-DL81ZX7NA5FBXUVJ8JH4/MrSpell0012.jpg Projects Using Bondo, I filled the corners and sculpted the bumps on the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290193600-VHTTZL1V6EJSUHYOWA12/MrSpell0015.jpg Projects With the handle in place, I cut a recess for the side knobs. The knob master was lathed from a piece of basswood. Bondo was added to make an exact fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290197507-YJP0CUL369NK6GW8OA4C/MrSpell0016.jpg Projects Test fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290197860-NBHYUH8G6CMEZ30K99C2/MrSpell0017.jpg Projects While all this was going on, I had ordered a 3D print from Shapeways of the front frame. It was much easier to get the geometry perfect in the computer than trying to sculpt those subtle curves by hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290201261-REWNXW3Y9ZLXB0QBHH45/MrSpell0019.jpg Projects The back of the frame has a raised panel that should snap into the face. I painted the top so I could stamp where I needed to cut. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290200534-96PAS2CLQSZN9OXNK40M/MrSpell0020.jpg Projects With the face marked, I could router out a channel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290203134-DCOMU6UM1E78IP8WSE9V/MrSpell0021.jpg Projects The track was cut using a drill bit in a Dremel tool with the tile-cutting attachment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290205579-FE6KR3HUYKHMT9BEXEQL/MrSpell0022.jpg Projects And the panel snaps right into place! This piece will eventually be held in place by magnets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290205501-20NDKKHN2EWLSH3SFQJU/MrSpell0025.jpg Projects Next I marked where the display window would be. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290208376-Y72EVELVZZXY5PZ3Q38D/MrSpell0027.jpg Projects I cut a recess so that a thin acrylic panel would sit flush with the surface https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290210191-0P85GF6Q85N2J53G3VZH/MrSpell0031.jpg Projects Utilizing my limited math-fu, I marked the location of all holes on the back ans well as the location of the battery door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290210941-8V3LTDK0UXXD9P3WPESY/MrSpell0032.jpg Projects Holes drilled. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290217473-REW7YNNNGEUO73VQS724/MrSpell0034.jpg Projects The battery opening was cut the same way as the display, with a recess so that the battery door would sit flush. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290191128-N1GOMYSEIKRO5QFCTBT6/MrSpell0013.jpg Projects I made the master for the battery door with laser cut icons glued to a piece of plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290217168-SQI8H5V3CJLOPSTUK6K1/MrSpell0035.jpg Projects The completed door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290227423-IQHGJ3MSXX7T7W0R24N4/MrSpell0042.jpg Projects Test fit of the door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290220199-QX1B3XALPRWBQ6RNO2P2/MrSpell0036.jpg Projects I cut a masking tape master to make a pattern for the feet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290221247-VMB8IC3SHXRV6XZH0K41/MrSpell0037.jpg Projects I then transferred the design to a sheet of 1/4″ Sintra. The Sintra was heated and bent over the base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290224602-K5XG52P0XYD31TAKK46W/MrSpell0038.jpg Projects Once that cooled, I cut a second piece, heated it and formed it over the first. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290224307-VROEW64N50VZZBAZ01Q9/MrSpell0040.jpg Projects Once glued, I rounded the edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290231844-NX3B44D9VCFK7OH9XOOH/MrSpell0043.jpg Projects Test fit of all the parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290231188-T2AAIU7DVPWB4M5A3DA2/MrSpell0044.jpg Projects Test fit of all the parts, as seen from the front. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290236351-HWXJIAZTDZYPR8VLK616/MrSpell0045.jpg Projects One last modification before molding was to drill small holes in the frame and body to house small magnets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290234082-GU8H9QIFI44AGN604TOU/MrSpell0046.jpg Projects All parts were molded in Smooth-On MoldMax 40. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290240713-KPAVAQMFG1YEKPUB6EB8/MrSpell0048.jpg Projects To make the different messages on the screen, I had film printed out at a silk screen supplier. On a standard 8″x10″ sheet, I was able to fit every piece of dialogue form the movies plus a bonus message! These would be cut out to be interchangeable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290245683-94GXJ1HEHZQKTF5AOQET/MrSpell0054.jpg Projects To light up the screen, I ordered a custom lighting rig from VooDooFX. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290245176-H5A9AN23DYHCFNEO5I94/MrSpell0055.jpg Projects A 9v battery runs a bank of super bright LEDs on an adhesive strip! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290252498-3NTR64D2ABL5INFLBIT6/MrSpell0064.jpg Projects After the body was painted, I installed the lights and then sealed the body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290250564-UXH1C7T97WR32EUG2T13/MrSpell0063.jpg Projects To get the proper color for the letters, I bought some aqua color acetate but it was looking too pale and green. I found that the blue plastic covering on the acrylic panel actually corrected the color! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290249545-N2LGKIJ3IBBZHDXR5ZNI/MrSpell0056.jpg Projects For the keyboard, I was able to fit the graphic on CafePress‘ large vinyl bumper sticker. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290253730-6X3NR3E5EDKJ7P8G1YFK/MrSpell0066.jpg Projects The final assembled copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290257086-KGSLDQVT16244GFQX0DM/MrSpell0067.jpg Projects And the screens lit up! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290256715-NDYNYEKYPUQZWIHKNNL5/MrSpell0068.jpg Projects Back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290260489-UEAH3KYA8OTN1E40E9OY/MrSpell0069.jpg Projects Bottom showing the battery switch. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290262381-09XPQ0LHXKY5P1IECCVR/MrSpell0070.jpg Projects Front panel detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524290263200-0AC6AN89TBEWAMJSCMY3/MrSpell0071.jpg Projects Handle detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323771650-4B59BH0KNWY72B66CO02/Brit-Cit0000.jpg Projects In February, the Replica Prop Forum launched a contest where prop builders were challenged to make a helmet from the Judge Dredd Universe. The winner would receive a prototype Judge helmet from the production of Dredd 3D. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323774418-DFXIWUQTJ7NFBRF92IR2/Brit-Cit0001.jpg Projects My concept for the contest was to adapt the comic book design of the Brit-Cit Judge’s helmet, so it works in the gritty, realistic world that ‘Dredd 3D’ established. I approached the design and build as if it was pre-production work for a much hoped-for sequel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323773566-BD1QJX7RO0S00RY6CTWO/Brit-Cit0002.jpg Projects For this design, I tried to retain as much of the comic’s style as I could. The original has the taller dome (which I’m sure is a nod to an English Bobby’s helmet) which I incorporated into the Dredd movie style helmet. Obviously, I needed to include the giant lion’s head as well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323776153-5E662YG643VFSSQ6G08J/Brit-Cit0003.jpg Projects I started by cutting profiles of the helmet from 1/4″ MDF to act as guides while I sculpt. I cut slots in each and slid them together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323779373-9L4226T9KJ9KIKSK6K46/Brit-Cit0004.jpg Projects I cut layers of 1″ insulation foam to glue into the profiles with casting resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323778862-7JZADDD42C3Y7LUTHQWW/Brit-Cit0005.jpg Projects Once the resin set, I could start carving away the excess foam. I used a belt sander to remove the big pieces and a blade for more detailed work. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323782922-6XJ6YWRDIBPG1YP8DAJ8/Brit-Cit0006.jpg Projects Once I got the basic form carved, I used a grill scrubber to knock off the edges and further smooth the shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323786706-N57YP3H15YSQD5JR24QH/Brit-Cit0007.jpg Projects Finally a rough sanding sponge further smoothed the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323786311-HRBR2NIHBKFYYKBFZGNJ/Brit-Cit0008.jpg Projects Once the foam was finished, I could see what needed to be fixed. I had some symmetry issues in the dome where I was too aggressive with the sander but it was more or less in good shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323790565-UBP7YLN6T7PLUMRY0DTH/Brit-Cit0010.jpg Projects Next I sealed the foam with acrylic paint and then added a light coat of Bondo over the entire surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323793840-N69HH7OHD8FWD4A35IIZ/Brit-Cit0011.jpg Projects As tempting as it was to work on the big lion face, to get the helmet symmetrical I needed to start with the dome. Both the right front and left back were not round enough so I had to add Bondo until they matched their opposite side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323795673-VEOCPK4I03EZZILN3FMM/Brit-Cit0012.jpg Projects After many hours of putty and sanding work, I got the helmet feeling round and smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323796881-UKR7YORFFP8XLE7I0UUY/Brit-Cit0013.jpg Projects Using the plans, I re-measured points on the lion’s face and made pencil guides for additional Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323799719-O8YOFHGEAL72BVELEY18/Brit-Cit0015.jpg Projects Once I had one side looking good, I made paper templates to use a guide for the other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323810986-558WGNLX2PNU7BFK4K2I/Brit-Cit0016.jpg Projects The whiskers, center crest line, and muzzle lines were scribed using a fine file. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323815387-OO5X16T0OJKPDR9N3TIT/Brit-Cit0017.jpg Projects For an object with compound curves like this one, a rubber, flexible ruler is perfect for drawing guide lines. I found this one at the local dollar store! For a dollar!! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323813313-FT6M701KSLKFWPWV2PJZ/Brit-Cit0018.jpg Projects The last detail to build was the raised level across the top of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323816801-GOXD0AQZYOEB55H59GPL/Brit-Cit0019.jpg Projects Recessing the eyes of the lion would be difficult to sand and clean up. To get around this issue, I cut MDF to the size of the eye cavity and vacuum formed the shape with thin styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323821126-TT5G9BADURN9X5IW5DUT/Brit-Cit0020.jpg Projects I cut holes slightly larger than the plugs in the lion’s face. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323819581-Y3PXVEZIAT0F3PQ4SHOH/Brit-Cit0021.jpg Projects The vacuum-formed plugs slipped into the holes and were epoxied into place. Any excess could be easily trimmed off after the glue set. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323822543-AZJIL9393FR86CULN8UW/Brit-Cit0022.jpg Projects To make the stripes on the top of the helmet, I cut some electrical tape to the size. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323826482-5O9PSNGLNTFQGAOXTL2U/Brit-Cit0023.jpg Projects The tape stretches over the complex curve and creates a slightly raised strip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323826301-5GY6SH78UEWSWHXR588I/Brit-Cit0024.jpg Projects The construction is complete and the helmet is ready to mold! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323837852-3GCR6KT8BJ8ZGM8TZIEH/Brit-Cit0025.jpg Projects I brushed on several layers of MoldMax Stroke to a thickness of about 1/2″. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323836978-TSGULG1E2YTY5VXESAJ9/Brit-Cit0026.jpg Projects I cut two pieces of 1/4″ plywood to make a parting line for the mother mold. This was placed over the center of the helmet and Plasti-Paste II was applied on each side to support the mold rubber. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323841344-X3XQF2PXZ0T29GTVDHPG/Brit-Cit0027.jpg Projects The mold could be peeled off the master like a sock so no seam line! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323843848-JS0SXO8SXAV646PKXEUT/Brit-Cit0028.jpg Projects With the mold re-assembled, I could roto cast a copy in SmoothCast 300. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323844116-2QRGRTVLQ7L7IEE1VCZJ/Brit-Cit0029.jpg Projects I bought a welding face shield to use for the visor. I cut a small piece and, after clamping it in place, I drilled mounting holes through the helmet and visor so it could be attached with pop rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323852682-2YGKXZXB3AIYUR7U2X6D/Brit-Cit0030.jpg Projects Since I’ll be attaching it before painting, I covered the visor with plastic wrap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323851086-SSUCMONA0N1UW6N7WAR0/Brit-Cit0031.jpg Projects I used a forstner bit to countersink the mounting holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323857119-2VQWL4NV7M2SGQPNVXXN/Brit-Cit0032.jpg Projects After the visor was attached, I puttied over the rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323855560-XGN45J8UY4C12SM0GK9O/Brit-Cit0033.jpg Projects The entire helmet was sprayed with primer to double-check the putty work. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323858737-3WCEEJGU7LWYLRVWJKLO/Brit-Cit0034.jpg Projects Since the helmet sits so high on the head, I needed to pad it so that it fits properly. I cut 1/2″ foam and covered it with foam backed headliner material (the cloth on the ceiling of your car). This pad fits at the top of the helmet with two extra discs of foam under it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323861676-YFP85R2TWTDUQHJI4T63/Brit-Cit0036.jpg Projects This piece of padding was constructed the same way and wraps around the back and sides of the helmet. I also wrapped an additional pad that sits in back of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323868964-MB94XO7C64QN21UBT82Z/Brit-Cit0037.jpg Projects The padding was attached to the helmet with industrial strength velcro. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323872867-PQ7C2PEW7RK2BYD93NMC/Brit-Cit0038.jpg Projects Here you can kind of see the padding in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323872641-LN56IMOOO8JN1IC24KPL/Brit-Cit0039.jpg Projects The paint scheme of the helmet was pretty simple, just black and gold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323875963-V3QQTI1H0IGPEYPBS0UA/Brit-Cit0040.jpg Projects After the paint had a week to cure, I clear coated it with Future Acrylic to protect the finish. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323876644-QMHZP7FSB7DVV3TX7T0H/Brit-Cit0041.jpg Projects Next, it was time to beat up the helmet with files, rasps and saws to match the battle damage on Dredd movie Judge helmets. Adding silver nicks and scratches and a level of Mega-City grime was enjoyable though. The gold looks better too! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323878372-WUPVFMDP09UWW9RHGDO0/Brit-Cit0042.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323879628-HRDGJ3EE40L02H09GS9I/Brit-Cit0043.jpg Projects Back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323881061-CP418UW15EXA8UZBEWSC/Brit-Cit0044.jpg Projects Left side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323885213-ZY0XDSP60XRLXKLOOYHV/Brit-Cit0045.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323887354-QSAX9QE2YGXG9VJJOQXW/Brit-Cit0047.jpg Projects My good friend Judge Rotzler was kind enough to pose for pictures while dispensing justice to Brit-Cit perps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323891616-5I1V4ZRP9OXJHELRHBGC/Brit-Cit0048.jpg Projects This helmet is actually quite comfortable to wear and the range of vision is much better than you would expect. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524323890998-AXINMEH02ZLHS0XA5QUJ/Brit-Cit0049.jpg Projects While we were at it, I had to try the helmet on myself even though my beard is not Justice Ministry regulation. It was worth the 8 hours in the isocubes! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524324932170-NHAO93JQJZWVUYDIZCT5/SafetySalamander_001.jpg Projects In the past, I would’ve looked forward to buying an action figure of this character. But since Playmates discontinued their World of Springfield toy line, I guess it was up to me! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524324932570-4VH307YWG7FFULUHOWMN/SafetySalamander_002.jpg Projects I started with a “Casual Homer” and added a piece of coat hanger wire to support the tail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524324936571-OLX7R2QT8U5U0005MJCZ/SafetySalamander_003.jpg Projects I added foil to flesh out the tail, covering it with Apoxie 2-part epoxy putty. I considered turning the tail down for stability but it just looked so much better up! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524324936155-E4TCW40F6Y1KNVSQUJ85/SafetySalamander_004.jpg Projects I used more epoxy putty to add details and flesh out the bulk of the suit. I was very careful to preserve the joints so the figure would remain posable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524324939203-TDJOPVD5JN0PJAHY7GMG/SafetySalamander_005.jpg Projects The neck was sculpted to preserve the cowl lines and minimize the seam and the lips, eye sockets and finger webbing was added with Apoxie. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524324939674-PCDMX4QZ6OQQHU2ZYYQS/SafetySalamander_006.jpg Projects The finished sculpt coated with primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524324941106-BLE86VMSNDLPL3AYLGYZ/SafetySalamander_007.jpg Projects The belt was made from .03 styrene strips and the belt buckle and badge were carved from thicker styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325827239-R527KBLYITL5Q8ARCSPT/Uruk-Hai_0001.jpg Projects I had some free time to build something for myself so I decided to make the Uruk-Hai Berserker helmet from The Two Towers. I started by creating a 3D model in Strata3D. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325827892-G9U3H4M9Q78ZQ6E22DRZ/Uruk-Hai_0002.jpg Projects Pepakura is a Japanese program that converts 3D models into paper models. Once converted, you print it, trim out the pieces and glue them together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325832630-JPJK5GJTV8BNATCJCDFF/Uruk-Hai_0003.jpg Projects I use cover stock paper for these models. It's not as stiff as card stock but stiffer than regular paper. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325832352-ND10GOAQ5DQ6TDIJ4TC1/Uruk-Hai_0004.jpg Projects This was the first project where I used Pepakura. It's some extra work but a good alternative if you don't have a 3D printer (which I didn't at the time.) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325835178-BCNIQPEC3W043RK31C1Y/Uruk-Hai_0005.jpg Projects The completed model. I built spacers to try to preserve the size of the openings. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325835171-7R3A2HLKNVTL985DC8C9/Uruk-Hai_0006.jpg Projects The paper spacers weren't holding the shape so I glued mixing sticks to them before slushing several coats of plastic resin inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325837724-34VJLX9PQGSOY338LY9Y/Uruk-Hai_0008.jpg Projects I sanded the ridges off the outside and used Bondo body filler to smooth out the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325840507-GSI824PIXCOX7KCG5W87/Uruk-Hai_0009.jpg Projects I heated up some thick styrene and shaped it to the back of the helmet to form this plate. Orcish craftsmanship means I don't have to worry about it being close to perfect! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325842369-CGJBE9XUONN79MHHXDSH/Uruk-Hai_0010.jpg Projects Using the paper model as a template, I cut out more thick styrene for the bottom plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325844452-GFQBRU929JNXWHO6YAFC/Uruk-Hai_0012.jpg Projects A coat of filler primer and a bit more sanding completed the main helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325846487-D1KRBPRR84QW5T3P1K6U/Uruk-Hai_0013.jpg Projects To make rivets, I used a pen cap to make dimples in some clay. I poured resin into the holes and got instant rivets! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325849041-FA0XVNFQKG38SN78M5BL/Uruk-Hai_0015.jpg Projects All the rivets glued on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325850248-LO4P0KAGHVQL1A6NJMQL/Uruk-Hai_0016.jpg Projects With the construction done, I applied a base coat of Hammered Silver, dusting it on to avoid the hammered finish. I used this paint for its durability. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325853834-GHFPMIM4RQ1O33K64TBQ/Uruk-Hai_0017.jpg Projects Next came a wash of black to knock down the shine and bring out the detail. I also added touches of rust. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325858148-JNRNL1J2I8XG28PAZL9Z/Uruk-Hai_0019.jpg Projects I cut a buckle from a scrap of steel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325853589-SKX81WSTOSC6217F5LUB/Uruk-Hai_0018.jpg Projects I gave the metal a rough hammered finish with a ballpeen hammer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325860016-JIYT9KBTETE2NGCHPS3O/Uruk-Hai_0020.jpg Projects I cut some wire and bent it to form the tongue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325862382-S1VSY03AEKZEKW3FGRDL/Uruk-Hai_0021.jpg Projects I punched holes in the other strap and gave the end a rough cut with dull scissors. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325867232-SFIH1SVHZY3IYJ4TCNTC/Uruk-Hai_0022.jpg Projects Once the buckle was in place, I glued the strap around it. To finish the look, I gave it a quick stitch with sinew. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325864519-KQNTAD86W6WCGN9EGPCA/Uruk-Hai_0023.jpg Projects The chin strap glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325866678-63B6SP71L0LICRK1H500/Uruk-Hai_0024.jpg Projects The final touch is a gentle application of the White Hand of Saruman. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325868419-IKRPXOYI26J8PAXS4HUM/Uruk-Hai_0025.jpg Projects The final helmet ready for war! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325871824-ZV7NKW9TESQXN5MNJ2KI/Uruk-Hai_0026.jpg Projects Front view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325871341-QNTFJIWMNI7H8ZG6Z4PX/Uruk-Hai_0027.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325874109-HD12Q6QN7GYW1NOS0DJT/Uruk-Hai_0028.jpg Projects Back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325873060-UPHPKJ2C1ECAPVW05C99/Uruk-Hai_0029.jpg Projects When I was building the General's variant, I realized the eye holes were the wrong size and shape. I cut styrene plugs and taped them in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325874020-I7QM24QZABVDUMTSEQWW/Uruk-Hai_0030.jpg Projects I glopped some Bondo on the plugs to get rid of the seams. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325874683-6Q6FC72Z7ZFJZITZVW1X/Uruk-Hai_0031.jpg Projects I sanded the Bondo to match the curve of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325874896-8001R2EQHEIAO6UG3ZQA/Uruk-Hai_0032.jpg Projects I drilled the new eye holes into the plugs https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325876088-7UU0RL4AQ52OD1ES8B8W/Uruk-Hai_0034.jpg Projects I removed the plugs and made a mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325875163-HLVC1J4M4G2O1KUAAZNF/Uruk-Hai_0033.jpg Projects The resin plugs snap right in place. These were part of the Uruk and General kits to correct my inaccurate eye holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325876291-TD4HODGD8LZ8RDAJVUQR/Uruk-Hai_0035.jpg Projects I painted the new master and made a mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325878445-ZMWK59252U37W9DNIDUC/Uruk-Hai_0036.jpg Projects The new copy was cold cast with aluminum powder so it shines up like real metal. My steel wool happened to have some rust on it so I got some free weathering. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325888513-OYYFS3SXI9FAYQQ0M5SA/Uruk-Hai_0043.jpg Projects The back plate had a thin spot in the casting. Rather than putty it up, I made it part of the damage. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325879928-MFX5Y6BHLJ84DFZOWYV2/Uruk-Hai_0037.jpg Projects The original helmets have the white hand crudely painted on so I used a chip brush to do a purposely crappy job of it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325881691-G96AGXV0ICPECKVVAMMK/Uruk-Hai_0038.jpg Projects The final helmet https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325881587-ULP4OJMB1IUML8YEOUKA/Uruk-Hai_0039.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325884246-SXI7F3IKB3ORDBMOA7GQ/Uruk-Hai_0040.jpg Projects The other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325883650-T1U4WZASHMDP5KFC7DDX/Uruk-Hai_0041.jpg Projects Back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524325888608-B67VGVAIMTEL7L62ZBPN/Uruk-Hai_0042.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524200991781-5DYULZVU5BNQVF02VMCJ/Izangi0001.jpg Projects I was commissioned to build the helmet of Izangi-no-Okami from the game Persona 4. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524200992830-PY6TA0TD6T16S20OW5HE/Izangi0002.jpg Projects Rather than a clay sculpt or Pepakura model, I decided to try something new this time. My friend Volpin uses a method where you print out a sheet of 1″ grid squares, cut a hole for your head and then take front and side photos with your head centered in the grid. Once imported, the images give you a scale guide for the size and dimensions of your head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524200993719-CH2PYRFSVTI3BZBGFTO4/Izangi0003.jpg Projects I traced the scale photo and then built the helmet around it. I tried to build in 1/2″ around my head to account for the thickness of the plastic. The risk in sizing it that tight is if you’re off, you can spand a lot of time, money and materials on a helmet that may not it when you’re done. On the positive side, since I’m using my oversized melon as the model, it should fit anyone else fine. There wasn’t much reference to go on…only a few production drawings and screen caps. Working with the client, I was able to work out the details and made changes to make it more practical in the real world. I shortened the blades hanging off the back of the helmet to a little over 4 feet and shorted the head spike by about 8″. It still has the basic look and now it will be more functional. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524200996223-Z6DA5F0XO5WDQWW3U9LP/Izangi0004.jpg Projects Using the printed plans, I cut profiles in 1/4″ MDF of the basic shapes of the helmet to guide the sculpt. This will keep the helmet symmetrical and proportional. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524200996178-4U94ZZ24TDSRWS6H7NFH/Izangi0005.jpg Projects I cut sheets of pink insulation foam and spray glued them into the framework. Small areas were filled with Smooth-On Expanding Urethane foam. It expands gently, filling all pockets. The aerosol expanding foams as found in hardware stores is pretty aggressive, and can push pieces apart. It is also crazy sticky and takes forever to cure. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524200998681-38OO88IBLI28LGIK0DI4/Izangi0006.jpg Projects Next comes the fun part…carving the foam to shape! Using a utility knife and the belt sander, I carved away all excess foam until I hit my MDF guides. Suddenly you can see what it’s going to look like! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201001415-5UC3Q2ASTEOGQ52HKNN4/Izangi0008.jpg Projects Since Bondo will eat into foam, I sealed it with a generous coat of acrylic craft paint. I also cut plastic inserts to fit in the eye and mouth areas. A small recess like that is hard to work in. The insert eliminates that effort and gives you a nice smooth surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201005521-W3NSWF0BG6ZANR4MZMNC/Izangi0010.jpg Projects Since the dimples would be difficult to get perfect by hand, I decided to make vacuformed plastic inserts to define their inner contour. Hold on to your brains…this gets tricky! The side dimples have a cylinder running through the center of the depression. To form this, I would need to make the opposite shape…a dome with a cylindrical cutout.I glued up a block of MDF, drew in the contours of the dome and then drilled out the location of the cylinder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201009130-9Y28BGIRWKKRCZAAYBD3/Izangi0011.jpg Projects Once the MDF was sanded to shape, I had a perfect cylinder already cut through the surface! This would have been difficult to cut after the dome was formed and would have demanded some cleanup. I sealed the MDF and then sanded it smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201009456-CV0NC2NJFUHWIWMU6D1O/Izangi0012.jpg Projects Using ABS sheets (textured side away from the master) in my mini-vacformer, I made perfect inserts for both sides of the helmet. A similar insert was vacuformed for the smaller, center dimple. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201013892-MZO987V3J2O77NSYB52Z/Izangi0014.jpg Projects I sealed the dimple foam and then glued the inserts into the helmet with 2-part epoxy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201014771-M5JU56MIPP9EB67ATDZI/Izangi0015.jpg Projects Duct tape is handy to keep parts in place as the glue sets! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201017901-1UUU3FH9VSYE161KV807/Izangi0016.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201006973-802105D19JMA6D1ITL3E/Izangi0009.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201017800-J8KMZ4D54VVP7V1M12RI/Izangi0017.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201020292-Z8LV08PL37OM6PM3DQIA/Izangi0018.jpg Projects I spread a thin coat of Bondo Auto Body Filler over the sealed foam, working for complete coverage as opposed to trying to smooth it with the first pass. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201020607-0TWTI84OPSMLJLCQMF38/Izangi0019.jpg Projects Much sanding and more Bondo later, I sprayed the entire surface with Filler Primer. This shows all the other surface perfections that you have to smooth out with more Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201021982-7J58Z0WRM6NM3PXQVWTO/Izangi0020.jpg Projects After I got all the big dents out, I filled the small holes with Bondo Spot Filler Putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201023247-R9I8Y1GWN1UPFKBL9XJE/Izangi0021.jpg Projects After the putty stages, I sprayed the helmet several coats of primer and then sanded it up to 1000 grit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201025265-E82L44VXIKP1TAKADOG0/Izangi0022.jpg Projects While I was working on the helmet, I was also building the blades that hang from the back of the helmet. Since the blades were over 4 feet long, they needed to be as light as possible but still strong. I finally decided to laminate two 1/4″ sheets of balsa wood together with fiberglass resin (pressed flat by my long press “Grond”). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201026469-5UMIJPG7LJHTTYRQNI5Y/Izangi0023.jpg Projects Once the resin set, I could trim out the blade profile and shape the cutting edge. Since balsa is so soft, I could cut it with a utility knife and plane the edge with a sanding block! These were the fastest swords I’ve ever made! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201028759-QNBDJ67KJL7CC71JL4IJ/Izangi0024.jpg Projects I drilled the holes in the handle which removed more weight. Now that the shaping was done, I coated the entire thing in more fiberglass resin. It soaks into the wood and significantly hardens it. The dried surface was then sanded smooth, with any pits filled by spot filler putty. By the time I was done, the 4 foot blade only weighted 4 ounces! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201032495-SJXWIRTH3DH9FFNCXM0Y/Izangi0025.jpg Projects The blades were painted with several light coats of Rustoleum Hammered Silver…light coats allow the paint to be applied without the hammered effect. The can is there for scale only. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201031138-O7QHNB9REOVXYQEXVDEF/Izangi0026.jpg Projects The cutting edge was masked off so that the flat areas could be painted white. You’ll see the final product at the end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201033613-2DVX9QLH2NA7YEH4C190/Izangi0027.jpg Projects To attach the blades to the helmet and, more importantly, to allow them to be removed, I bought a spring link and a bit of chain to harvest links. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201036909-E44ZVRG9FQ52IRZ55YNV/Izangi0028.jpg Projects I cut off one of the links and glued it into a dowel, the intersection smoothed with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201036572-PARN7Q9Q96SW5L76NSHJ/Izangi0029.jpg Projects I made a containing bracket for the spring link out of MDF. I knew I was going to mold this so I made it in two halves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201038684-MR5ELW5JV2KS5EGK2GKL/Izangi0030.jpg Projects I forgot to make holes in the helmet for the hanging hardware so I had to (carefully) drill cavities in each side, using dowels to ensure that they were protruding at the same angle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201041040-WIBVCEGBLR8XRE8SCBZB/Izangi0031.jpg Projects Meanwhile I used Bondo to blend the bracket into the spring link. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201041231-LAVHDWZTSKG78L0Q64MC/Izangi0032.jpg Projects By coating the link with mold release, I could remove each half of the bracket and have perfectly fitting cavities https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201043190-XMISN0HHWWWWV23CDOBQ/Izangi0033.jpg Projects A quick test fit of all the hanging hardware. So far so good! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201044300-6ZHDHHT42NPCUB70LUI4/Izangi0034.jpg Projects I used Bondo to smooth out the inside of the hanger holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201046989-0B8JK06G7IHVA14QHBZ3/Izangi0035.jpg Projects The final assembly.   https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201071009-Q6TIDPN97W3WC8FKXB7X/Izangi0052.jpg Projects To attach the blades to the helmet, I needed a metal ring of a specific size. I looked and looked at every hardware store I could find but no luck. Then I remembered the old “cut-a-spring-into-links” trick! Exactly what I needed! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201070635-EWXJ4Q3Q8JKO8YJVWDLW/Izangi0053.jpg Projects The ring was threaded into the blade hole with pliers and then it snaps right into the spring link! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201046876-T31WIVM90O9861H3APDY/Izangi0036.jpg Projects I cut the sides of the head spike from 1/16″ styrene and glued them together at the proper angle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201048761-VPZ2AIRVE0MEWUYN5PFQ/Izangi0037.jpg Projects To get a nice strong seam, I poured Smooth-On Smooth Cast 65D into the intersection.   https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201052898-AI0W8IX8D491JYDBUUS7/Izangi0039.jpg Projects I used more styrene to seal up the spike. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201054121-LM7EILQ2NI8LQQB7BT0K/Izangi0041.jpg Projects I added wooden dowels as glue pegs so that the spike could be easily attached to the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201056201-VBJGB5EVEY53GXRIQR6Q/Izangi0042.jpg Projects Now that everything was built and sanded smooth, it was time to make the mold of the helmet. I cut a hole the shape of the helmet’s profile in 2″ insulation foam and sealed the seam line with clay. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201056095-LWI3J1EF6BUZTQEZC6XH/Izangi0043.jpg Projects I brushed on a thinned print coat of Mold Max Stroke brushable silicone rubber to preserve the surface detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201058590-M7EMLG2FG6ESCHC9ZUZ7/Izangi0044.jpg Projects After the molds on the helmet and spike were built to a good thickness, I made support shells with Plasti-Paste II. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201059752-V2NW2HWAMU8DT22SGN76/Izangi0045.jpg Projects I slush cast 65D resin in the mold and popped out a beautiful copy of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201062760-G3QELM1MW8O7ITJIDGGZ/Izangi0046.jpg Projects The back of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201062190-7A75B3BIJSUG9OAHLXSJ/Izangi0047.jpg Projects Since the neck hole is too small for the helmet to fit over the head, I had to cut off the lower plate and clean up the edges with putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201064576-MX8IZYTDBO0KAX0UZWVT/Izangi0048.jpg Projects To re-attach it, I added a styrene hook to the back and tabs with rare-earth magnets at the front corners. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201066866-MZZFTG2QMTN6QNEILY5B/Izangi0049.jpg Projects With the head spike attached, I gave the helmet a coat of white paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201066881-00XN1X1G88XXEHHXLJ5A/Izangi0050.jpg Projects Next I masked off the white areas and painted the lower half with Hammered Grey paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201068693-3DNOY2MDI0JEOENYKJN2/Izangi0051.jpg Projects To fit the lenses, I cut some 1/8″ red acrylic to roughly the size, softened it with a heat gun and pressed them to fit from the inside of the holes. Since the fit was specific to each hole, I marked their identity with a black China Marker (which is a wax pencil). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201073114-0GFWTU3Y7T7A30UWU0T5/Izangi0054.jpg Projects The lenses were backed with mirrored window tint so hide the eyes inside and then were attached with hot glue.   https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201073655-Q5GQ5D69E0WPGWJC2JGH/Izangi0055.jpg Projects After a quick test fit, I discovered that there wasn’t much air coming into it. I cut a hole under the nose so the wearer could breathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201074837-5DRT0ASX510RI247K2TT/Izangi0056.jpg Projects The final helmet! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201075604-EVY1LGL7K7HEZ5MCRL7Y/Izangi0057.jpg Projects Here’s me wearing the helmet. Not much beard room but the visibility is pretty good! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524201077065-V6Q1IAZUF6P3CTZ4JSOT/Izangi0058.jpg Projects The blades are so light you can’t tell that they’re back there. Just don’t forget and sit down! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202797816-D7244MGZPYUI32RMNUUB/TD01.jpg Projects One of my favorite TV shows is the cartoon Jackie Chan Adventures. I watch the entire run every year and love it more with every viewing. Besides great stories, comedy and action, the show has beautifully designed props that I covet greatly. As to not deny myself any longer, I decided to build the Talisman Detector. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202798151-T2SW2412F7QV6S8V7RDO/TD02.jpg Projects After drawing out the plans in illustrator, I cut the handle parts from basswood. I used small wooden dowels to strengthen the glue joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202798831-0HP4JXTTYH6A0ZQ6YHFC/TD03.jpg Projects A bit of wood glue and pressure from a clamp completes the base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202799642-3S88UCZNZ68XQNWKD659/TD04.jpg Projects My friend Fev was nice enough to laser cut the decorative bits from thin hobby plywood. Since I needed 4 sets, this saved me tons of time hand cutting and they are perfect beyond what I could do by hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202799848-1ID4RV1UOSG070H6C378/TD05.jpg Projects The assembled handle! Now the easy part is done. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202800584-D27PLB5FHWIB4WX66E97/TD06.jpg Projects After a less than stellar attempt to sculpt the dragon head master in epoxy putty, I decided to model them in Strata and have them 3D printed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202800584-HCI4QVCW3R4ZWAQFR19H/TD07.jpg Projects Working from my blueprints, I slowly worked the detail into the dragon. Fortunately, Strata allows you to work on half of an object and it mirrors the geometry for a perfectly symmetrical sculpt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202801310-34EOPKSLK68QHG2ISCU4/TD08.jpg Projects To save on printing costs, I made the dragon 2mm thick. This will be plenty strong but will also allow for the thin spots to meet minimum printing requirements. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202801576-E5QDPKVCBRN04OLMBSNI/TD09.jpg Projects A few weeks later, I got the master back from Shapeways. I printed it in their “White, Strong and Flexible” material. With the polished option, there was very little to clean up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202802163-XMIM31MDHYVYKADK9PT7/TD10.jpg Projects The 2mm wall thickness was crazy strong!   https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202804064-JNIPT5Z7DXDXVCE5ZPA3/TD12.jpg Projects I made a silicone mold of the master so that I could make four resin copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202807221-BRT4ZWBIMM8QBPZQD350/TD17.jpg Projects I made a silicone mold for the handle using MoldMax 40. The resin will pour in through the base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202808104-FX9ZVSFRPKUXRLV4QTLX/TD18.jpg Projects Even with a 1″ core of foam, the cast resin handle has some nice heft! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202808162-1RXYWFB4ZJMJBMBS9RDK/TD19.jpg Projects A simple base coat of green, a wash of dark green to bring out detail and a matte finish completes the Talisman Detector. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202809816-RQGSYQ6IWIRUUWUHN0B2/TD20.jpg Projects The final assembled prop. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524202811743-22IVDAODDG51MPVJ5C2J/TD22.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327210050-PV8ZQ2GAJYOGTD60UV3P/Herugrim00.jpg Projects I was commissioned to build a scabbard to fit the United Cutlery replica of King Thèoden‘s sword Herugrim for a collector in Canada. Since I also own the sword, I jumped at the chance! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327209833-Q9HTVM7RRDJ8N6LZFRK4/Herugrim01.jpg Projects After drawing up plans based on the available reference, I cut the sides of the scabbard from 1/8″ Baltic Birch plywood, adding a 1/4″ around the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327214154-PD9M9XCRFSIZGSNY7V2N/Herugrim06.jpg Projects I measured the thickness of the blade to gauge how much space needs to be inside the scabbard. You want the scabbard to be snug enough so the blade won’t rattle but not too tight where it can’t be easily drawn. In addition to the blade itself, you also need room to add cloth to protect the finish of the steel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327215097-D8OAO40L859REIDUDVTO/Herugrim07.jpg Projects I cut strips of poplar to make the sides of the scabbard and glued them to one side. I glued in panels of black moleskin to each side of the scabbard. The moleskin (not real skin of moles) is very thin but soft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327215242-DV2OU0CEPF6YEFGGMWH1/Herugrim08.jpg Projects The scabbard “box” was glued shut and then the edge was rounded with a router. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327213665-6Z7VOHVG41CLNUGLUDLU/Herugrim04.jpg Projects A quick test makes sure the sword fits. I used Bondo to fill any gaps along the edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327227502-PS9SD282XURMEPKIUFSV/Herugrim10.jpg Projects I found some leather in a local upholstery shop that turned out to be a perfect match! Strangely enough, the employees were not shocked that I walked in with a sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327228923-QC46XPJ0T9IRP2O3G2RN/Herugrim12.jpg Projects After a few failed attempts at stitching the leather on the scabbard, I decided to just glue it so that it would have a perfect seam. Just in case there was a gap in the seam, I pre-painted the wood a reddish brown to disguise the seam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327230200-F33OM250QBM6MQMWH3WM/Herugrim13.jpg Projects I glued each side and slowly worked the leather around the scabbard. The leather stretches so it was not hard to get a nearly invisible seam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327230773-PYQZI4NHJFR2YRQ8DIC5/Herugrim15.jpg Projects I broke the part down into sections for modeling. The large horse is the same on both sides so I built it as one piece. The trim and the two smaller horses is symmetrical so I could work one side and let the software duplicate it. The edges were left for last. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327232838-D5IVAZCGMR2Y0M45NGSF/Herugrim17.jpg Projects In sculpting the main horse, the software smooths the edges between polygons so you can describe curves with simple geometry. The purple lines are designated as hard edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327236839-7FBYX0GNTFGFNI97BVSL/Herugrim20.jpg Projects The final model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327250530-8N6QRMMB487FUKQ8N80O/Herugrim24.jpg Projects Two weeks later, I had a 3D print of the tip. I also printed up a reverse model of the main horse. Bernard Hill (and King Thèoden) is left handed so when he wears the scabbard (on his right side), the main horse faces down. The client is right handed but he wanted the horse to also face downward. I made this reverse horse as a replacement to address this issue. My copy will be as the King wears it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327257581-FQAV788AVIGQHOLA55WR/Herugrim29.jpg Projects Concurrently, I started working on the cuff at the opening of the scabbard. I cut thick styrene to shape and heat formed it around the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327272707-EWVEF83QCO95CSZUZ5K0/Herugrim35.jpg Projects A second layer of thinner styrene was cut out and heat formed around the first layer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327274897-AL55BJMRQVWJUH3MGRC3/Herugrim37.jpg Projects A third layer was being difficult so I applied a layer of Bondo and trimmed it to form the decorative terracing design. The inset stars were cut out of styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327282256-Q5OLBDUL6VLY7JN9YMVP/Herugrim41.jpg Projects The final cuff ready for molding. I cut a piece of foam as a stand-in for the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327284280-ZTZVYFFK01457FWLIWM2/Herugrim42.jpg Projects I poured silicone for each side. Acrylic cabochons were used for keys to align the mold parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327283691-XO2KHNDRF78Q857CU1JI/Herugrim43.jpg Projects After each side cured, I disassembled the mold, removed the center foam piece and poured a silicone plug inside the cuff. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327285041-SNKC92MLWVC7CEGSU33Y/Herugrim44.jpg Projects My first test pour in the reassembled mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327285628-2X0LTC19SVC1PZJZURNL/Herugrim45.jpg Projects Thankfully, it fits! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327285930-9J8457G99Y4Y0BVLAQRV/Herugrim46.jpg Projects I bought some brass powder and added it to the resin (a process called “cold casting”) to cast both the cuff and tip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327289027-IHG5YX716FNDXNVTH0M8/Herugrim47.jpg Projects Some buffing with 000 steel wool, and the real metal shine comes out! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327288783-2CNUJEBMQVNZDLZSV4Z0/Herugrim48.jpg Projects To bring out detail and add some wear-and-tear, I painted the pieces with a wash of black acrylic paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327297953-UOHB88VVLO9VFFAY86U2/Herugrim49.jpg Projects Some more buffing with steel wool, removes the surface paint but leaves it in the recessed bits, showing all the detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327296183-3Z9WL50KZT99I9F6IWUX/Herugrim50.jpg Projects The pieces glued on the scabbards. On the reversed client’s version, I had to remember to put the leather seam on the opposite side so it wouldn’t be seen. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327303358-TP25BGL1DNPUEF9DON01/Herugrim52.jpg Projects The last detail added were some brass rings for the belt straps (which I hope to make as well). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327308672-299AS2QFYYZCER31F8PK/Herugrim55.jpg Projects The completed scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327301908-TNBPLWA90GOTLKUTLHEZ/Herugrim53.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327312189-MZB0IIHVBO7VEAAE5I6I/Herugrim54.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327311794-WN29JBWI0NUMJP2DS87U/Herugrim56.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524327314734-YBI6N4F1LVHHBZIIBG7P/Herugrim57.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528078063-6NR0EMJ178LXSWQNQ9F3/Yu-Gi-Oh0001.jpg Projects I was commissioned to make the Dueling Gauntlet from the anime Yu-Gi-Oh! This project presented a few tricky technical issues: The cuff needed to fit the arm tightly but needed to be removable. The client also requested that the stars be removable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528076659-GALH0F7XAF9E1VSICKOK/Yu-Gi-Oh0002.jpg Projects Planning was critical so it took some heavy figgerin’ to correctly size and space the stars around the cuff cylinder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528078615-GVJROO63AHTM9PPFELQE/Yu-Gi-Oh0003.jpg Projects Another issue was to distort the stars so they would wrap around the cuff. To figure out the geometry, I built the cuff in Strata 3D. As flat stars the “arms” would poke out of the curved surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528079393-1ZOLNNW1D8Z6LHF3FXUX/Yu-Gi-Oh0004.jpg Projects I built extra thickness to the stars so that I could move the arms back. The extra thickness would also help durability of the stars as they’re handled. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528080054-4U3E3X0HCLOY85NB9GPE/Yu-Gi-Oh0005.jpg Projects Once I was happy with the new configuration, I exported the star and ordered 3D printed copies from Shapeways. For a few dollars more, I can get them polished so all I’ll have to do it throw them in silicone. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528083723-6KPS3RAOFFTH05X198TL/Yu-Gi-Oh0006.jpg Projects To test the cuff, I framed it in thin MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528082193-M9H765UW1A0FQDYKUPZ2/Yu-Gi-Oh0007.jpg Projects My math worked out and the prototype was, indeed, wearable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528084166-R7ADERYC7Z3N9CZ82CKP/Yu-Gi-Oh0008.jpg Projects With that out of the way, I could make the cuff master. I glued two piece of basswood together and lathed a cylinder with the right diameter. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528089091-NBVHXO9ZS8FZG7SY66GF/Yu-Gi-Oh0009.jpg Projects After the ends were shaped, I slowed the lathe down and sanded it up to 1000 grit. Finally, I sprayed it with filler primer and buffed it to a shine with a paper towel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528090101-E1M0UHJDEFMMP0YLHI30/Yu-Gi-Oh0010.jpg Projects I drilled out the center, and marked the halfway point with tape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528092230-4M8Y9E8AYUHS74FS2FNZ/Yu-Gi-Oh0011.jpg Projects The cut cuff master. The theory was to make one half of the cuff that could be duplicated to make the whole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528092577-JQRJD59H703DK9F5K8I3/Yu-Gi-Oh0012.jpg Projects A quick test fit to prove it was still wearable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528094541-A3LKDOKEKSN4MGHLKZEB/Yu-Gi-Oh0013.jpg Projects To eventually lock the cuff halves together, I made a key out of 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528096672-K9HMF35I5LFEG5H6SNON/Yu-Gi-Oh0014.jpg Projects To make the female end of the lock, I pressed the male end into a lump of clay. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528097308-GMQ99HC6MG73ENVSKB2P/Yu-Gi-Oh0015.jpg Projects I poured some resin into the mold to make a copy of the key, then carved a hole in the other end to make the female end of the lock. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528100193-YP95GISUJGU99RBZJKU5/Yu-Gi-Oh0016.jpg Projects After glopping some Bondo into the hole, I pressed the resin key into it, making sure the edges were aligned. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528099954-MJI6O4L208PTZQJDFH1C/Yu-Gi-Oh0017.jpg Projects A few minutes later, the resin is removed and I have a perfect female end of the cuff lock! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528101832-5QO0K1CN1SB93XDJN25Z/Yu-Gi-Oh0018.jpg Projects A coat of primer and the body of the cuff is done. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528104366-BIMHL6KNSFOJ8DVQPWX0/Yu-Gi-Oh0020.jpg Projects I printed out the star placement from my plans and wrapped it on the cuff, marking each star’s location with small punctures of an Xacto knife. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528106986-14V3BRZ9UU77PYIPFAMH/Yu-Gi-Oh0021.jpg Projects About three weeks after I ordered them, the 3D printed stars arrived from Shapeways. I also had them print a stamp for the holes that was 1mm wider than the stars. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528108105-Y0N6V5V41CIETY3IVVHN/Yu-Gi-Oh0022.jpg Projects I drilled out holes in the cuff that were just big enough for the stamp to fit inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528109287-51NBDSXK3CTGTWH49Z3E/Yu-Gi-Oh0023.jpg Projects With the stamp in place, I marked where each point of the star should hit. The black mark designates which point of the star is “up”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528113339-GT0122D84FLBT9TXZ83Q/Yu-Gi-Oh0024.jpg Projects I mixed up a small quantity of Bondo, dropped it in the hole and then pressed the stamp into it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528112459-XK2RBXBD1JXFFQJC3H6F/Yu-Gi-Oh0025.jpg Projects When it was removed, I had a perfect hole for the star. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528114865-SBN1JLOUKZMZ5VPKKVU3/Yu-Gi-Oh0026.jpg Projects It’s always important to check your work. The star fit inside the hole perfectly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528116085-ZCO10Q9SP302B77H7A61/Yu-Gi-Oh0027.jpg Projects Once all the holes were stamped, I sanded the Bondo flush with the surface of the cuff. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528117963-LB47VWXD64PJIQ7ET1D8/Yu-Gi-Oh0029.jpg Projects To make the inside of the hole cleaner, I glued in a piece of styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528104690-L8UMTBNNGSOBFDOTQ378/Yu-Gi-Oh0019.jpg Projects Meanwhile, I also lathed a master for the knuckle plates from basswood. They are about the diameter of a nickel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528121086-BZAO991RDZLGU8Y0FV4O/Yu-Gi-Oh0031.jpg Projects I drilled holes into each star recess to allow magnets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528124105-SPAC76SS5LNZJEX926SA/Yu-Gi-Oh0033.jpg Projects With all the masters finished, I made silicone molds with Smooth-On MoldMax Stroke. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528131052-TQ1H52XZOAYGHFFZJR91/Yu-Gi-Oh0036.jpg Projects I mixed brass powder into resin to “cold cast” the knuckle plates and stars. These were polished to a metallic shine with 000 steel wool. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528133679-5HUZPZ8TH6MQVT4QOY4H/Yu-Gi-Oh0037.jpg Projects Each star had a hole drilled in the back so that a nail head could be glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528134881-BQZHCGFT5PJE3YPUIJ26/Yu-Gi-Oh0038.jpg Projects This would allow the star to be held in its hole by a rare earth magnet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528138267-68QX63791WSBFC6T74V3/Yu-Gi-Oh0040.jpg Projects Two resin copies were pulled from the molds and luckily, they fit together as planned! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528142318-DTISX0XGCMWMGQDQDT0Q/Yu-Gi-Oh0042.jpg Projects During the cleanup process, I drilled holes for rare earth magnets at each key. These would hold the cuff together snugly while still allowing the wearer to easily remove it when needed. I also added Bondo at the seam to reduce its visibility when the cuff halves are together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528144711-3UY9Q9QAOULK05V4Z2XO/Yu-Gi-Oh0044.jpg Projects The cuff was painted with several light coats of Rustoleum Hammered Silver. The light coats give you a durable metallic finish without the hammered look. The final stars are in place but apparently not oriented in their holes correctly in this picture. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528146273-F2NMAA2KWS2EXCLYFBJK/Yu-Gi-Oh0045.jpg Projects The client supplied some cotton/nylon gloves that would need to be dyed a burgundy color to match the anime. The Rit Dye website has handy formulas for mixing custom colors. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528149272-4DQYMY0GI56UXMQS4WSL/Yu-Gi-Oh0046.jpg Projects I heated some water on the stove to 115ºF and added the dyes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528153525-YLECPDOCMPO22E16VXK2/Yu-Gi-Oh0049.jpg Projects The resulting color was very close to the reference. I ended up dying all four of the supplied gloves. The color turned out slightly different on each which gives the client final choice for his cosplay. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524528154829-UGT1UA50LLBY2FGL7POW/Yu-Gi-Oh0050.jpg Projects The final Yu-Gi-Oh! dueling gauntlet! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547711359-M95EANA1NMR2LKVJTICR/GoW_Shotgun0001.jpg Projects I was commissioned to build the sawed-off shotgun from the game Gears of War. The challenge of this build would be to make it open to accept shells. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547711627-O9UI17AOB5BS3HCLLUE3/GoW_Shotgun0002.jpg Projects I started by gluing two ABS pipes together and adding a piece of MDF to create a flat surface on the bottom. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547712773-Q59ZLVVBWU3B5IJ9HDC0/GoW_Shotgun0003.jpg Projects I further built up the barrel support with MDF, using Bondo to make a tight fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547713336-0X18TFYM3MLG3YEKW1QN/GoW_Shotgun0004.jpg Projects A PVC pipe was used for the magazine tube (although this shotgun is a breach loader and doesn’t feed ammo from a magazine…for lack of another name, I’ll call it a magazine). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547714338-LXOZPGNY25WHU0CLG9ER/GoW_Shotgun0005.jpg Projects To make the hinge for the front assembly, I epoxied and bolted a PVC pipe. This part will be taking a lot of stress so I wanted to make it as strong as possible. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547714843-2S3ZCS5XKSASTRNTN7EE/GoW_Shotgun0006.jpg Projects I notched the breach and inserted PVC pipes for an inner barrel. Bondo and styrene finishes the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547715526-PO28W5U1MELR8JVFQ43Q/GoW_Shotgun0007.jpg Projects I inserted MDF plugs in the side of the hinge with holes to accept a long bolt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547716318-5FUBWPOHU8DLMZVPRDY3/GoW_Shotgun0008.jpg Projects The fore grip was initially framed out with 1/4″ MDF so that it fit snugly against the magazine tube. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547717056-5QPRAUFLVIBVYWH19TG8/GoW_Shotgun0009.jpg Projects More MDF was added to flesh out the fore grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547717318-1BBSYLQNO8SGSYG3CZMR/GoW_Shotgun0010.jpg Projects To frame up the pistol grip, I used 1/4″ MDF bolted to a walnut dowel. I cut the trigger from 1/4″ acrylic and the trigger guard was cut from 1/2″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547718583-8NHG3KDJ7FEDEK2J0KOT/GoW_Shotgun0011.jpg Projects The shotgun grip features cylindrical chambers at the breach that would house the firing pins (on a real gun.) Since you only see one side of the cylinder, I could make one master that has an identical left and right side, and then make resin copies for use on the replica. I routed grooves into an ABS tube and lathed a cone for the end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547718315-NA79SDN6Y5552CKUX8YH/GoW_Shotgun0012.jpg Projects After the trigger guard was sanded into shape, I added a styrene lip to the inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547719456-XO1IK4A57B4OVIF2QVH0/GoW_Shotgun0013.jpg Projects I started fleshing out the pistol grip with MDF, carving out a recess for the chamber cylinders. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547719890-YYCKQ7N8NFYMVGKXWCOS/GoW_Shotgun0014.jpg Projects Here are all the layers for the pistol grip! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547720264-33REZ2GHTSBETO3IO6C3/GoW_Shotgun0015.jpg Projects I heat formed thick styrene around the grip dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547721261-1FC7J75BE7TIK49D9DOT/GoW_Shotgun0016.jpg Projects I glued more MDF together to make the outer grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547721257-LN18R6R1WO9QMGILFFNK/GoW_Shotgun0017.jpg Projects Once it was fitting properly, I shaped it on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547722163-QITKO384VH79I1VC0AII/GoW_Shotgun0018.jpg Projects The shotgun shells would be built around a wooden dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547722405-23PAFPMSXDZIGPDBZA94/GoW_Shotgun0019.jpg Projects The dowel was clad in ribbed styrene and the end was heated and folded over. I wasn’t that thrilled with the fold so I would have to recreate the end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547724021-QMBHE4JZIU029654I7SA/GoW_Shotgun0022.jpg Projects I used epoxy putty to re-sculpt the shell end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547732312-M6IJ91GJR9O1NEYMT2HM/GoW_Shotgun0036.jpg Projects To make the end of the shotgun shells, I had an acrylic disc laser engraved. I based the engraving graphics on a Remington shotgun shell. After consulting with the client (who knew the material much better than I do), we decided to make the shells hold 10 gauge shot. The “HS” on the Remington stands for “Home Security” which seemed to work for this as well. The “BS” stands for “Blind Squirrel” since the Remington puts the line brand there. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547739227-I3DGZX2HGTFB99V1MN88/GoW_Shotgun0048.jpg Projects I molded the shell master so I could make resin copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547739217-M25ENAFG5UT9DZ5BZRO9/GoW_Shotgun0049.jpg Projects I slush cast some Smooth-On 65D in each side and inserted an insulation foam core to reduce weight and reduce the amount of resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547744327-JBJVDI6F4PMF8VXOVG8E/GoW_Shotgun0056.jpg Projects Once the shells were painted, I gave them a wash of black to bring out detail and give them that end-of-the-world feel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547723068-POSLEFPYUJ9LV8MZBSAM/GoW_Shotgun0020.jpg Projects I carved some MDF to make the grip detail and added some metal hardware that looks similar to the reference. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547723639-CNROQ704AJSVIPJ12E03/GoW_Shotgun0021.jpg Projects The pommel was lathed from walnut and would be secured with a screw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547724643-8YC1N6JH3O7LTXXYNNUR/GoW_Shotgun0023.jpg Projects The chamber cylinders were finally glued into place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547725077-B3ZBXXM3KLIWFYM21QHL/GoW_Shotgun0024.jpg Projects I heat formed thick styrene around the MDF of the pistol grip to make the cover. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547725524-Y360MNJHG4Q2JHCD35MU/GoW_Shotgun0025.jpg Projects Since heat forming is done with a heat gun and my hand, there are plenty of imperfections to Bondo out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547726142-JS713UGWRLZJV4RDBTE1/GoW_Shotgun0026.jpg Projects The hinge was made from cherry, epoxied and screwed for maximum strength. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547726378-E30YXQOYGAH7FJWX9VOW/GoW_Shotgun0027.jpg Projects The hinge was glued and bolted to the barrel assembly, puttied smooth and coated in primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547727170-T5XMRCLZYXTFXS8Z9T9Z/GoW_Shotgun0028.jpg Projects Since I hadn’t yet figured out how to keep the breach closed, I had to cut into the MDF of pistol grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547727286-NZGJER34M1J5GYGSM3Z0/GoW_Shotgun0029.jpg Projects I used a piece of poplar attached to a spring to act as a latch. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547728631-Z0VEUTH25LROAFKC9UQ5/GoW_Shotgun0030.jpg Projects The latch would hook onto a hardwood block that was glued to the barrels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547728624-TQYBGKDED045N8ARALZ5/GoW_Shotgun0031.jpg Projects Styrene and hardware details were added to the fore grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547729979-TNEXGN0UPTQDM3Z4ORP1/GoW_Shotgun0032.jpg Projects Styrene of various thicknesses were heat formed and added to the hinge plates. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547729873-M54CZH8XIEOP07070W85/GoW_Shotgun0033.jpg Projects I bought some steel mesh heat shielding to wrap around the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547731376-7Z5C6XYDKIUDL5RBOZNW/GoW_Shotgun0034.jpg Projects I bent some steel wire to make the pommel D-ring. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547731117-XS8H3KMX7ZII5U2R1E6P/GoW_Shotgun0035.jpg Projects I drilled holes and added half round styrene piping to the outer grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547732636-MBJ4AATMFY7Z2O6U7I0M/GoW_Shotgun0037.jpg Projects To make a sliding switch (for what we assumed was a safety), I glued two “L”-shaped pieces of metal together and made a styrene rail for it to slide along. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547733688-6G8VILVQTBJ7Q76GP33A/GoW_Shotgun0038.jpg Projects I cut a channel for the slide assembly into the MDF and then glued it in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547733573-G94L6IVSJHHCA1OQF9CQ/GoW_Shotgun0039.jpg Projects I cut a piece of poplar for the sliding button. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547735010-FM6J363YL1S6Y2U3JWHW/GoW_Shotgun0040.jpg Projects I cobbled together the hinge nuts with MDF and various bits of hardware. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547734752-F0GYWAN6Y0FXSCZ7N1E8/GoW_Shotgun0041.jpg Projects The top rail was made from wood and the joints were smoothed with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547735959-LOSDZUNXJ8GN2EWQFIGA/GoW_Shotgun0042.jpg Projects The bottom of the gun features a presumably movable lever which I cut from a piece of irrigation tubing. To attach it to the gun, I cut a piece of wood to strengthen the connection and hold a pair of metal brackets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547736174-606SSL4QETLWGKUKOQ0E/GoW_Shotgun0043.jpg Projects I chucked a piece of thick styrene to the lathe and carved a custom rivet that would be duplicated in resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547740808-5753QVR18569PQ91E8LM/GoW_Shotgun0051.jpg Projects Here is a painted resin rivet glued onto the fore grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547736641-NKZ1XN7PH9LDTSEBS4HI/GoW_Shotgun0044.jpg Projects The tip of the magazine tube has a row of vents that would be extremely difficult to accurately cut by hand. Instead I modeled the piece in 3D and had it printed in plastic by Shapeways. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547737167-V5U4XISCLAOGFE1QMZO0/GoW_Shotgun0045.jpg Projects To finish the magazine cap, I lathed the tip form a piece of wooden dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547737624-O79F53NPI380GZ8K77H6/GoW_Shotgun0046.jpg Projects The assembled magazine tip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547738089-BHHL61NGTDLU7T86OKT8/GoW_Shotgun0047.jpg Projects The lever would swivel on a brass rod between the two lower tips of the hinge. I used styrene plastic spacers inside the aluminum tubes so the pieces wouldn’t rattle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547740484-8BTNGQRHTFFFWPXNN70Z/GoW_Shotgun0050.jpg Projects Although it was pretty strong, I was concerned that the wooden latch wouldn’t hold up to repeated use. Using it as a template, I cut a new latch from a 1/8″ piece of steel bar stock and glued on the thumb tab. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547741748-J12LI2VUQSSBME43SINK/GoW_Shotgun0052.jpg Projects Now that everything was working, I could glue on the pistol grip cover. A generous slathering of Bondo along the seams hides any gaps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547741859-X870RQ9HND56AH4KRU7E/GoW_Shotgun0053.jpg Projects I added some half-round styrene edge piping and rivets (made from tacks) before painting the grip with primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547743061-PO6DR12BC6OWL4CRJCCD/GoW_Shotgun0054.jpg Projects The base coat for the gun was Testors buffable Metalizer Gun Metal. Since I used a dark grey auto primer, it didn’t take much paint to cover it. The paint can be buffed with a paper towel to get a realistic gun metal sheen! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547743403-6KLXGRPNV93VKEWICFME/GoW_Shotgun0055.jpg Projects To weather the gun, I dry brushed silver acrylic on any edge that might get scuffed. I also gave all surfaces a wash of black to simulate grime and grease. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547749101-IRSP9V2DCFXU40L0S7TL/GoW_Shotgun0062.jpg Projects The final gun and shells! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547744561-UV4NIOMN6UR3CAIVJ4UA/GoW_Shotgun0057.jpg Projects The breach opens to load. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547745854-QC8A6QCGGB0F6MVD28W8/GoW_Shotgun0058.jpg Projects Ammo loaded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547745819-YTMJ0W44W78LN7ICOYQ9/GoW_Shotgun0059.jpg Projects Detail of the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547746868-2ITNLK0F08LQTLTMOGIJ/GoW_Shotgun0060.jpg Projects Detail of the hinge section. A last minute addition was a laser engraved black leather strap made by my friend Fev. What it’s for is anyone’s guess. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524547747095-2179HBFG5XA401T684TR/GoW_Shotgun0061.jpg Projects The muzzle of the shotgun. This project was a huge engineering challenge for me. I could plan out the appearance but how the parts would fit together was figured out on the fly. I’m just relieved everything works! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893858164-W5POO4FVY13TNP267JXE/dragon_egg_0001.jpg Projects I absolutely love Game of Thrones on HBO (and I’m working my way through the books, but not fast enough to spoil the show). As soon as I saw Daenerys Targaryen pick up a dragon egg, I knew I’d have to make one (or three). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893847128-PCL23S0480S0L0Q5B4KV/dragon_egg_0002.jpg Projects I started by cutting 3/4″ MDF into discs that could be glued together on a threaded rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893863685-DVZKX3PLAQIZ73532G4N/dragon_egg_0003.jpg Projects Once the pieces were glued together and locked tight, I added end caps so I could chuck it to the lathe https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893884393-49RROEENI03F64YALOEF/dragon_egg_0004.jpg Projects A quick spin on the lathe formed the MDF into an egg shape. Since this will be covered in epoxy putty, I didn’t have to worry about making it perfect. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893876350-D1VT9JOGB8S776W95M2A/dragon_egg_0005.jpg Projects I started by adding epoxy putty to the bottom and creating a stone texture with a silicone stamp – I molded a big rock out in the yard for occasions like this. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893905850-GPTJMLKJWWVLUHOUA2RD/dragon_egg_0006.jpg Projects Once I got to the putty stage, I could take the egg with me to work and add putty during my lunch hour. I could usually create four rows of scales per hour. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893917175-T9VOC9H324BZTO7279PX/dragon_egg_0008.jpg Projects I kept the scales around the same size by comparing them to a plastic template. I had some sanding and cleanup still to do before I could make a mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893948687-EZGHWJAT0RFHTN5BF47L/dragon_egg_0010.jpg Projects The mold was created in two parts with Smooth-On Stroke brushable silicone with a support shell of Plasti-Paste II. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893980294-NI8YH6FNRKNMC1BV2GES/dragon_egg_0014.jpg Projects Here are both sides of the mold removed from the master and turned inside out so I could more easily apply baby powder to all the nooks and crannies. The baby powder breaks the surface tension so that you don’t get bubbles in your resin surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893979344-M6QCV5O0RMW9AN0GKHI2/dragon_egg_0016.jpg Projects I slush cast Smooth-On Smooth-Cast 65D in each side getting as close to the edge as I possibly could. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524893993188-DARUCQVRR5VHFFESMNMD/dragon_egg_0017.jpg Projects I mixed up a last batch of resin, dumped it inside and then sealed the mold. I rotated the resin around the seam until it cured. When I popped the egg out, I had a nice hollow resin copy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524894003556-OVJA5UNGGPSLKZR6WHU6/dragon_egg_0019.jpg Projects The seam turned out pretty good with only a bit of clean-up to do. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524894027221-144KXBTGWNSI49GTS1YR/dragon_egg_0020.jpg Projects After casting three copies, I gave them all a coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524894020153-VG9B5U4AVIL0EBL79G6D/dragon_egg_0021.jpg Projects The final painted eggs. Each egg was sprayed with a base color coat, a dark wash applied to bring out the recessed details and some dry brushed lighter shades on the raised surfaces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524894047141-O49ZNP04XYYIPLW8M4KB/dragon_egg_0022.jpg Projects Detail of the stone texture. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524894042586-AGYRB4B1GTVUTAW0JHHZ/dragon_egg_0023.jpg Projects Detail of the top of the eggs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1524894059048-D557LQ0QCAQ9H8J6TZLV/dragon_egg_0024.jpg Projects The egg in relation to my hand. The final size is about 6″ x 8.5″. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414162991-HTUFJRU8FYPZ1K3ZQNFI/army_hand0001.jpg Projects I was commissioned build Ash’s mechanical hand from the movie Army of Darkness. This was a fun one to build as I love this movie too! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414163055-G9TQ1YCDNY32ZLSSKLOU/army_hand0002.jpg Projects I started the vambrace (part that covers the forearm) by lathing a MDF master that roughly matched my forearm. I heated thick styrene and wrapped it over the form. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414167031-GOXKOFO1XI6I548ZLQUC/army_hand0003.jpg Projects Once I had both halves formed, I taped them together and trimmed the ends to the proper length and angle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414167031-7VDC6N8SS1JENSLBWZT7/army_hand0004.jpg Projects I riveted hinges to the inside of the vambrace. Unfortunately it caused too much of a gap and it only allowed limited range of movement when you open it. I eventually popped them off and mounted them to the outside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414172073-W84LVIM8NAMN00PZFVZJ/army_hand0005.jpg Projects I needed very thick half round piping for the edges of the vambrace, well beyond what’s commercially available. I took a plastic tube of the proper diameter and pressed it into some clay for a temporary mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414172717-4P9F54CYEHIQHLA9OFFV/army_hand0006.jpg Projects I poured some SmoothCast 65D into the temporary mold and a few minutes later I had my half round ready for mounting! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414174678-RILT6SJ2L6EBNDM1TTTP/army_hand0007.jpg Projects I glued on the piping and the flaws in it gave it a cool hand forged look…as if I had actually planned for it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414174970-28RJ82GOR3JQJSAGDQAE/army_hand0008.jpg Projects For the cocking mechanism frame, I cut strips of 1/4” acrylic and made all the appropriate screw holes and slots. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414176280-6U1HGRMQ35X2ZB7KEBT0/army_hand0009.jpg Projects For the large rivets all over the vambrace, I used paper brads. I drilled a slot where I wanted a rivet, dropped some glue in the hole and then inserted the metal prongs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414177258-0I42SNNFVBX19W66IEM7/army_hand0010.jpg Projects With most of the major construction done, a coat of primer allowed me to do final cleanup. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414177936-XFXZU2SHP2X61M7FQDNU/army_hand0011.jpg Projects To keep it closed, I consulted my friend Giles who works at the Royal Armouries Museum in Leeds, England. He was able to supply me with lots of photos of actual armor and how they closed. I used a modified approach and used a rivet to create a pin on one side that would go into a depression on the other side, holding it closed. The pressure of your arm in the vambrace keeps it from slipping out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414180950-7DVRO8FFGN2SHGTILLCW/army_hand0013.jpg Projects Now it was time to make the gauntlet. I wanted to finish this within my natural lifespan so I bought a meat slicing chain mail glove for the base of the gauntlet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525472714954-4EZJSI62YCE24YMX4QZT/army_hand0012.jpg Projects I cut some posterboard for a template to cut the plate sections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414181486-3KZT0473Q4WI7KPLEJ91/army_hand0014.jpg Projects Wearing a knit glove under the chainmail to insulate me from burns, I heated some thick plastic and wrapped it over the back of my hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414183603-V5R60SI1AHJSBLLO0VUH/army_hand0015.jpg Projects I repeated this process for the inside of my hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414183810-Z8C526H9M8CVL0Q8OAZ8/army_hand0016.jpg Projects I added hinges to one side and used the vambrace pin enclosure method to keep the hand plate closed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414185845-V6SJ5CY5NHQ1VAPJQIEZ/army_hand0017.jpg Projects I heated more plastic and made the plate for the back of the hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414185994-5NCQKFUJJ4VL6IPKZKGW/army_hand0018.jpg Projects I cut nail heads to act as rivets along the edges of the hand plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414188557-JDQPVOKM8A75QF1RXA8O/army_hand0019.jpg Projects To make the compartments that contain pistons on the back of the hand, I framed out the boxes in styrene and used epoxy putty to build up the inner and outer edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414188347-1WDX91ZQXQFKRWQB3EQO/army_hand0020.jpg Projects More nails disguised as rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414191638-N7RKZ6682F9JD4SC1FNZ/army_hand0021.jpg Projects I heat formed some thinner plastic over a dowel and then cut sections for the finger plates. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414192165-Y22UBZ077YLQUZBMTB25/army_hand0022.jpg Projects The plates were painted with Rustoleum hammered silver paint, drilled some holes to mount them and then stitched them to leather strips. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414194598-83FBL0TTRD88WZJS68XJ/army_hand0023.jpg Projects Each finger got seven plates so I had to be careful when I sewed them on to keep even spacing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414195142-93CVHV6F3W1QZ0KEXM64/army_hand0024.jpg Projects I then hot glued the strip on to each finger of the chain mail glove. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414197080-UG53CFH9F2294NFC1YIB/army_hand0025.jpg Projects A quick test fit of the painted hand plate over the completed fingers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414197510-SIPTBKVS8NKHP5TJIND0/army_hand0026.jpg Projects The thumb had a special plate over the knuckle that would have to be fabricated. I made a few attempts at making the ridges with putty but they didn’t have that “hammered over a form" look. I decided to hot glue some half round piping over a MDF dome and vacuum form over it. Since this was a one-off piece, I didn’t bother to make the form look nice…it just wouldn’t show in the final plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414198529-6CYFJFSRLAGCB744XG2N/army_hand0027.jpg Projects I used a (filthy) scrap piece of .04 styrene and it seemed to capture just enough detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414199882-C262DG0LMCCNESZ4A4Q6/army_hand0028.jpg Projects Fortunately, both plate and buck survived the process and once it was trimmed out, it was ready for painting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414201101-TDNZ9XMHF6PY9QXTT70O/army_hand0029.jpg Projects I took two longer finger plates, sewed them to a leather strip and then glued the assembly to the glove. I then sewed the thumb plate directly to the chainmail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414202435-54RJPBATSSYVR5IMDT33/army_hand0030.jpg Projects A master piston was created by lathing grooves into a plastic tube and slipping it over a bend brass rod. I made a mold and cast 4 copies in resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414203886-XL4AT4D3ND53OMYS33ZJ/army_hand0031.jpg Projects The pistons where painted and given a wash of black acrylic to bring out the detail. Sharp-eyed readers will notice an extra piston. It never hurts to make extra as long as you’re at it. You never know when a knife will slip and screw up a part. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414204636-TC8SF0W8DZSTUR6177UD/army_hand0032.jpg Projects I glued in the pistons after giving the glove a wash of black acrylic. It really added depth to the boxes where the pistons sit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414206220-5SZ4HEQYI7D1LZQT2BEG/army_hand0033.jpg Projects I looked for metal bar stock for the hinged metal brace that attached to Ash’s arm but everything was too thick or too thin. I eventually decided to use thick styrene and paint it to match the other parts. I hinged it with a screw post. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414207728-V40XQ70E43UXMGPRJTVM/army_hand0034.jpg Projects I bought some leather straps and attached buckles to them. I search high and low for the buckles they used in the movie but I couldn’t find a match. The client wasn’t that concerned with screen accuracy so he approved these. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414208493-RUO8B5XEDT33XJNKOP8C/army_hand0035.jpg Projects A quick test fit allowed me to punch holes for the buckles to accommodate a range of arm thicknesses. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414210790-BB3A2E9OXM6VWOA5KORR/army_hand0036.jpg Projects To make the cocking arm on the vambrace, I bent a 1/8" thick bar of aluminum and added a strip of steel with a pop rivet for the side pistons to attach. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414211142-CKVD9442MVLFFEQWU6K2/army_hand0037.jpg Projects For some reason I didn’t take pictures of the mechanism, but here is the final result. I used two torsion springs around the main axle to make the arm return to a close position. It’s not very strong but it’s strong enough to keep it closed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414213930-F4MOUE7GRICFR9XKDWEF/army_hand0038.jpg Projects The arm in an open position. The ends of the side pistons (actually steel tubing with a plastic tube collar) were attached to a bar that slides along the groove. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414213934-SBIRVZY7BJN2HMJN84PF/army_hand0039.jpg Projects The client felt that the hand pistons were stick up too far from their boxes so I 3-D modeled a smaller, thinner piston and had copies 3-D printed at Shapeways. Honestly, I should have done it this way the first time. Much, much faster and cleaner. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414216771-IUOO1TY2BOLDS5ILM91N/army_hand0040.jpg Projects You can see how much better the printed piston fits in the box compared to the old ones. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414217194-9BD574EKTYRZX39JZKVT/army_hand0041.jpg Projects A shot showing a test fit of the new pistons. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525414218269-1NCLJPRDU5PQSN2SAS3U/army_hand0042.jpg Projects The final Army of Darkness mechanical hand…ready to wear and smite deadites! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564137292-TVI71T9SJ5O9Q3MUZ23G/Vacuum_0001.jpg Projects I’ve had quite a few projects where a vacuum forming machine would have been a huge help. It wasn’t until I found a great site with a step-by-step tutorial on how to make one from scratch. Unfortunately I neglected to take photos during the early stages of this project. Due to limited space, I decided to build my machine where the oven would hang upside down over the forming surface. I built the supporting table high to alleviate too much stooping over. The vacuum surface is 21.5″ x 21.5″, made with MDF and covered in aluminum. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564138309-2PKZZZJOZOR9SIFITCDM/Vacuum_0002.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564139966-04C3UQTHV66W6P64IKHH/Vacuum_0003.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564140902-0UA6FYPXANTH9UWLL9OD/Vacuum_0004.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564144511-4GX9NB8DCJ7035GQW08G/Vacuum_0005.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564144750-004K6VBGFXBQZ1HLS1JT/Vacuum_0006.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564149267-RAK2TUB0ZKC6UIXOTBWP/Vacuum_0007.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564148804-MRLO4IOHXXM0F0EJ9CIK/Vacuum_0008.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564152201-H8A2VQLKGN6EO3WPX3C9/Vacuum_0009.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564153768-3XGFBRLJPL2DZD0Y6Y7E/Vacuum_0010.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564156515-KZS84HUDPO8HREVXNLWE/Vacuum_0011.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564158354-LEVAYRKLUAYIG2F9JTXJ/Vacuum_0012.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564162618-0K07RO9DSQSMRFOT50PX/Vacuum_0013.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564165770-AJU7TV5DYAUT8WQYCD1P/Vacuum_0014.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564166802-9Q0PXWHUBOJKZUMX004S/Vacuum_0015.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564168838-M7POQZJ77TI513C0I8X4/Vacuum_0016.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564171060-CW3VIL1SPGHE2DPJ0Q79/Vacuum_0017.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564172124-TA2UB0OAFKQ7KB6PMWD2/Vacuum_0018.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564176694-B2CDCOX6L4WH669P0R5A/Vacuum_0019.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564176702-Z6EM0SODLJN001DZQYKF/Vacuum_0020.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564180077-KTIKB4TMTVDJUO29GTAH/Vacuum_0021.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564180209-APA3H4C9K3MF27YSTDM2/Vacuum_0022.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564185553-7O9NFB4XS0X5JXTQ4FSQ/Vacuum_0023.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564185175-F6GAVR07OIS8JXD47M2N/Vacuum_0024.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564188767-MQ0NLQ3X0BDU2I77UTUW/Vacuum_0025.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564189174-YBQKU3K9KM7QJKT5AX9Q/Vacuum_0026.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564192659-SERGOVSUJHUYICD0I1AV/Vacuum_0027.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564193261-ERT8NLI9WTYOKJT6YQD6/Vacuum_0028.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564196051-DEW3GK3XBFTF5GBW9RC9/Vacuum_0029.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564198069-0B2OG56B93DNBQ1YDPXP/Vacuum_0030.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564200912-33Z2K30W8HX46D7046NE/Vacuum_0031.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525564202247-1RBVIFJKMA5EPUGRI9NF/Vacuum_0032.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482171763-83014QV9GLL83Y93G6UH/Fallout_0001.jpg Projects I was commissioned to build the Laser Pistol from the video game “Fallout”. The client requested a light in the muzzle and sound when the trigger is pulled as well as a working battery compartment and two batteries that could fit inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482172127-3GT8P7PC9HXIRDEQ5EDX/Fallout_0002.jpg Projects With plans generously furnished by my friend Volpin, I started by making the body of the gun from 1/2” MDF. The edges would be rounded on the router table. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482172752-PVIZ1HAY9ZENLK4NMWLF/Fallout_0003.jpg Projects I made the muzzle cowl from 1/4” MDF, leaving it unattached from the body so it would be easier to work on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482172990-70X7E43JANVRMNNLXTOS/Fallout_0004.jpg Projects I rounded the inside corners of the cowl by plopping some Bondo inside and rounding the corner to the proper radius with an aluminum tube. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482173905-801L80V7HRPDMV0Y7ZIM/Fallout_0005.jpg Projects Once the Bondo set, I removed the tube and trimmed away the excess. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482174072-UL8Z3S6J6775FBHCJ7O7/Fallout_0006.jpg Projects I then shaped the outer radius on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482175159-WBAAZVFE6ZZDBAT8VLKX/Fallout_0007.jpg Projects I glued blocks of MDF to the body to form the raised areas on top and surrounding the butt plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482175319-JU5SE8Y8IJIJIZ4ZMV77/Fallout_0008.jpg Projects I chucked a router bit into drill press and carved out a decorative panel in the top. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482176392-S7X52ST0QO7TMAPVEMXO/Fallout_0009.jpg Projects More rounding of corners on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482176798-X2TLHL8EJRXP0JTA9JMS/Fallout_0010.jpg Projects I cut the front plate of the muzzle assembly from 1/8” styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482177531-JKEDQ0IJ92UDI8DVEBP3/Fallout_0011.jpg Projects I heated more styrene and formed it around the front plate. Once it was the proper shape, I glued it in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482178062-96T1L3S6CRLT6AO8MWK9/Fallout_0012.jpg Projects I cut the back of the sides to the proper profile. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482178417-BIZVAQ5BMNJQ0QHZKJXC/Fallout_0013.jpg Projects I cut plates of styrene to form the detail on the base of the front plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482178917-4ELYS4A6J26WEGRQK7GN/Fallout_0014.jpg Projects Since the front plate is thin, I cut wood screws down with the Dremel… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482179290-3QOG0HZ44LIEJPYCUWZ8/Fallout_0015.jpg Projects …and glued them into countersunk holes on each side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482179808-RII6YRK6446ZEG0LVLT1/Fallout_0016.jpg Projects To make the dish-like recess for the muzzle (where the laser beam comes out), I cut a hole in the front plate, globbed in some Bondo and pressed it into a dish with a spare acrylic gem. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482180276-2PTWPCPX840G788LKDC3/Fallout_0017.jpg Projects The resulting dish. A 1/8” hole was later drilled into it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482180846-SYVYGMOYRO88P5HCJ9BU/Fallout_0018.jpg Projects A detail block for the front plate was cut from MDF with a grill cut from styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482181533-PC5S3J9FTMSN50Q6VZ7B/Fallout_0019.jpg Projects A quick test fit of all the pieces so far. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482182280-19GOHHFBTCQP67TX29UK/Fallout_0020.jpg Projects I lathed the piston that stretches from the front plate to the grip out of basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482182799-J06X9SXJ99GPEHTI3W0O/Fallout_0021.jpg Projects The piston was glued into the recess at the back of the front late. A detail plate cut from styrene was glued on top of it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482183201-NSKUS7WOFUZJDETA74HF/Fallout_0022.jpg Projects I ordered a light kit from VooDoo FX that was pre-wired per my specs. All I needed to do was install it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482183695-6LSHINLSXXFYHOLM0ZWG/Fallout_0023.jpg Projects MDF details on top of the cowl. The seam lines were scribed on my Dremel router table. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482184796-ZB733JFG8P2IIY669BON/Fallout_0024.jpg Projects More MDF details for the sides of the cowl. The pockets were made with the Dremel sanding drum and a steady hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482185219-U0IUO9HSE2UV8EZMG18U/Fallout_0025.jpg Projects I lathed the (what I believe is a) range finder from a poplar dowel and flattened one side for attaching to the cowl. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482186515-LND766NR0NXUVIHN5B38/Fallout_0026.jpg Projects I left some space behind the front plate so there would be some ambient light coming through in addition to the primary light out the muzzle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482187013-512UYKRUXK5I24LR2WB7/Fallout_0027.jpg Projects I cut fins from styrene and glued them into the cowl. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482188203-UJ7M37MJSJLB3670J474/Fallout_0028.jpg Projects I framed the layers of the butt cap with 1/4” and 1/8” MDF, cutting a hole for the battery compartment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482188418-1R7J107X6LQCU0QRPI57/Fallout_0029.jpg Projects I cut the battery compartment door from 1/8” styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482189438-176J08BAW5QBGUNPXBIN/Fallout_0030.jpg Projects Decorative “rivet” holes were cut into the door with a router bit chucked into the drill press. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482189652-Y82TO6O0I5OMZ23ZNGDL/Fallout_0031.jpg Projects A removable cover (to allow access to batteries) was cut from 1/4” MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482191490-R93IBSATIHZRSSDONHXE/Fallout_0032.jpg Projects I cut the outer frame of the cover from 1/2” MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482191599-ALROYEHTHOKKRITTMIVI/Fallout_0033.jpg Projects The cover assembled with an interior block of MDF to build another level. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482192514-ADF8PRYMYVTLFJUXGAPA/Fallout_0034.jpg Projects Styrene details, screws and a clicking knob were added to the cover. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482192806-M67MLB1YMHHJO9YI9MZS/Fallout_0035.jpg Projects I added styrene strips to the side of the control knob to make grips. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482193491-R56P0WZC7NF0CNANSR4Q/Fallout_0036.jpg Projects I made a master for the battery with a block of basswood and styrene half round piping. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482193868-GG0KPQMO5TJ5NBWYQSGE/Fallout_0037.jpg Projects I molded the battery body and cast two duplicates in plastic resin. The battery terminal rods were made from wood dowels, and cast in resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482194311-RN2KSMZCVZQHHB6RA8EI/Fallout_0038.jpg Projects I made a battery holder from an old hard drive case. I glued in a strip of half round to keep the battery from sliding out once seated. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482194786-X0IBTJMQFIMXUN0PPUV0/Fallout_0039.jpg Projects The battery seated in the holder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482195283-HY5XNP9Z6ZLBDSNAN590/Fallout_0040.jpg Projects The holder was hinged at the top and equipped with a spring to grip the battery. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482195917-Q7Z6WA6RODYQ980DBT1D/Fallout_0041.jpg Projects I shaped the base of the pistol grip from a piece of 1/2″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482196299-K2R27SLG0P2E7YL561OI/Fallout_0042.jpg Projects Test fit of the grip in the base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482196765-LA00B14DLY9TXFU24SW2/Fallout_0043.jpg Projects The last piece of the pistol grip was made from laminated 3/4″ MDF with styrene panels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482197891-I1TDYPTEYIS3M6R7P57J/Fallout_0044.jpg Projects I attached the battery door with a small brass hinge. I cut a recess in the door and end cap to hide the hinge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482198261-DL5JTNI6R20FYFSPRSRJ/Fallout_0045.jpg Projects I used Bondo to cover the hinge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482198725-RKAVBVUGGRTMOG18X6ZK/Fallout_0046.jpg Projects A test of the hinged door. It still works! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482199285-G5GFB408P8MFP6IPAM35/Fallout_0047.jpg Projects And the battery still fits. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482199876-7L8YOY2NK3SBQ2JUHY3C/Fallout_0048.jpg Projects View of the seated battery when the door is closed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482200294-TJJ4ZC9RYI8HGVWM337D/Fallout_0049.jpg Projects A few last details: Half round styrene piping around the end cap and a few real screws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482201007-NIGWIX5VJHKHF2GSG016/Fallout_0050.jpg Projects Since the trigger moves laterally instead of rotating, I cut a piece of drawer slide. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482201496-OR0TNHORSOWL0BD8N2JC/Fallout_0051.jpg Projects The trigger was made from pieces of MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482201864-PWHWJIYL8JLHQ5YNC7HE/Fallout_0052.jpg Projects The drawer slide mounts to the top of the trigger. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482202457-SNWC0ZUB0GIFKNWYY72M/Fallout_0053.jpg Projects The trigger in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482202876-319HRVHQH4KFV2FGP63D/Fallout_0054.jpg Projects A small spring keeps the trigger in the forward position. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482204069-VTAEOH2E5DYHPA9K620F/Fallout_0055.jpg Projects For the sound, the client found a recordable greeting card. He was able to hook it up to his computer via mini-usb and load the actual laser gun sound from the game. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482204083-RN5ISZGT5PJYUMT83NP7/Fallout_0056.jpg Projects The speaker mounts under the gun behind the cowl. I cut a piece of metal grill from an old car stereo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482209171-V52ER2LD38YW6IYD2873/Fallout_0057.jpg Projects The speaker and grill. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482209429-O041OEY25KSY19W2JBLB/Fallout_0058.jpg Projects Real batteries fit below the fake one. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482210609-NDZYU18UYCVNSM50SO18/Fallout_0059.jpg Projects I used an aluminum tube to mount the pistol grip and ran the switch wiring down the center. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482210745-9QX8NJ4WPSQEI1WA8AAE/Fallout_0060.jpg Projects The completed base of the pistol grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482211970-96Y1NE07O5KD7TOFOM1U/Fallout_0061.jpg Projects The side vent was made from 1/4″ MDF with styrene inner vents. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482211948-O7KLYRHFR1FUK8R1O87W/Fallout_0062.jpg Projects The top vent tube was made from a piece of dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482212989-LCRI7IH75W1KN5W2D7OB/Fallout_0063.jpg Projects Some nails standing in for rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482213215-6S8R1R681UAXYI70XGPI/Fallout_0064.jpg Projects The side tube was lathed from a piece of basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482214476-ZCIXX8OATYTLDDY9WWFA/Fallout_0065.jpg Projects I cut out a 90º piece so it would mount flat against the corner of the body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482214633-NZBQHP8AVFTFQLCI6TWB/Fallout_0066.jpg Projects I used masking tape and heavy coats of primer to create inset panels in each side tube. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482215651-NW0M9TLXSEVPVYNUVJND/Fallout_0067.jpg Projects A base coat of paint on the gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482215994-IDB9LQCEZUCP7LMFR5SC/Fallout_0068.jpg Projects The graphics proved too small for cut vinyl masks so I used laser printed labels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482216361-QYXSJE6PU0M60FYFZ5XA/Fallout_0069.jpg Projects For the cable cap, I glued two disks together and filled the step with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482217047-0E59OE9LMBNHUWU30VBC/Fallout_0070.jpg Projects I bought a marine battery cable and attached it to the top of the gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482217402-YLY6GHO6EFOOU38QWEP6/Fallout_0071.jpg Projects Some strategically-placed “rust” painted over the base coat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482218053-QH7M6T1PGJINXPH50ID0/Fallout_0072.jpg Projects A layer of dry brushed silver to simulate heavy wear. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482218555-Z2UZJ83BTLHOHUZDHFK8/Fallout_0073.jpg Projects A final layer of grime and “grease”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482218964-QMI0G4TDBWXO3OES0KA1/Fallout_0074.jpg Projects The final pistol. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482219590-RFVK2VL8ICWTX308H64B/Fallout_0075.jpg Projects Back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482220171-Y3P399IUROK7VHT4YGHI/Fallout_0076.jpg Projects The rear cap is held in place by magnets so the batteries can be replaced. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482220446-OVL97COZQX4ESGB57L61/Fallout_0077.jpg Projects Weathered batteries. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482221674-JXBXRN9J4XTJF282YLRC/Fallout_0078.jpg Projects Detail of the end cap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482221780-3JI63ZIGRQ6LMOBG4GHS/Fallout_0079.jpg Projects Detail of the muzzle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482222958-GP6X45GRGES8L7DUSITY/Fallout_0080.jpg Projects The light activated! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482224840-M6OTMDMD99YSPJJO2AO8/Canary_0001.jpg Projects I was commissioned to make a pair of throwing stars for a Black Canary cosplay based on the Comi-Ame statue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482224591-JVP8148E7066ZKL1BH06/Canary_0002.jpg Projects Since these stars were mainly for conventions and photo shoots, we decided to save some money by making the stars out of flat 1/4” poplar. The diamond profile of the statue’s stars would be more difficult to replicate and is really more of a sword/spear feature…I suspect it would mess up the aerodynamics if you were to throw them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482226923-M7EY4WC3TYEUYD0JSGMW/Canary_0003.jpg Projects I did narrow each point from the center on the belt sander to make them look more sharp. The star may be blurry but look at that plywood table edge! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482227489-40II0WPBUF5TSPHJQWW7/Canary_0004.jpg Projects Finally, I drilled out a recess for the hub on each side with a forstner bit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482229815-HWHLV0GNJJK0VSDG957D/Canary_0005.jpg Projects The stars were painted with light coats of Rustoleum hammered silver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482230310-YA9GUE6ARB5AOKOV7I7D/Canary_0006.jpg Projects I lathed the center hub master from a chunk of MDF and decided to add a small Black Canary logo to the center. The cops gotta know who pinned the jewel thieves to a wall… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482232131-22G5H7SLVVNF54Q0ADRD/Canary_0007.jpg Projects The thin styrene logo glued to the hub. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482232596-J42F4E00S4DITKOV26KJ/Canary_0008.jpg Projects I made a silicone mold of the hub to make resin copies for each side of the star. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482235055-3QCMH2K56UH848FIYHPA/Canary_0009.jpg Projects A nice base coat of gold over the resin copies and hand painted logos finishes the hubs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482235289-5EDNL1M1V78RJUOXDBUF/Canary_0010.jpg Projects The final stars. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482237076-8W9KDM9RYF92DXIHCZC5/Canary_0011.jpg Projects Detail of the hub area. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482058852-TTL64O50LK6DDYJR1IX9/Bushido_0001.jpg Projects I was commissioned both masks of Mr. Bushido from the anime Mobile Suit Gundam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482059431-RIQTC75JMT6YO6E7X4L5/Bushido_0002.jpg Projects I decided to use Apoxie Sculpt (epoxy putty) to sculpt the mask master. I used this air-dry putty over clay because my sculpting skills aren’t good enough to produce a finish smooth enough to simulate metal. The dry putty can be carved, Dremeled and sanded to a smooth surface before it is molded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482061822-P4T445QHEO959J0Y8OFN/Bushido_0003.jpg Projects Since Apoxie takes a few hours to dry, I used Bondo to correct geometry and reshape features to make the mask symmetrical. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482061822-HD2NXR6W4N5EUSY71GDU/Bushido_0004.jpg Projects You can see from the pink Bondo areas how much had to change from the Apoxie stage to get to final sculpt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482064426-9SM1R068ABF9O1W0VK0Q/Bushido_0005.jpg Projects I gave the mask several thick coats of filler primer to smooth out the surface and point out any imperfections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482064404-PO40LY3D41QYO7XVE6KU/Bushido_0006.jpg Projects To further define the bevel around the eyes, I scribed a thin line around the color break. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482066560-RGM9VETJJAF2G1KIFEF4/Bushido_0007.jpg Projects The final mask ready for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482068157-2HSQ25TQQRI5GLCWLH0N/Bushido_0008.jpg Projects I used Smooth-On Stroke to build a thick silicone mold over the mask. The stuff goes on like cake frosting and allows you to quickly build a stable mold wall. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482069596-17GY76HH7L934QHHPFTC/Bushido_0009.jpg Projects I soaked a cheap shop rag in plaster to make a mother mold over the silicone so that the mask can retain its proper shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482072181-KZ4QGLBQMF6NLG81LZDC/Bushido_0010.jpg Projects The cured mold pulled off the master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482072418-UCKY6ER7UPQGAD92YA6V/Bushido_0011.jpg Projects I poured some Smooth-Cast 65D (formerly Smooth-Cast Roto) and slush cast the mask in several layers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482075076-V7SHX1PE2SA1L4LFVGMY/Bushido_0012.jpg Projects The de-molded mask! A perfect copy including my eyes and mouth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482075304-ROORD6102MI3ET6Y8WDY/Bushido_0013.jpg Projects For the half mask, I cast a second copy and marked where I’d need to change it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482079282-Q16RFM0WNHIXBHJZ43N5/Bushido_0014.jpg Projects The half mask with excess cut away and the scribed lines filled with putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482080260-DVIL64Q491GUO4C11UGG/Bushido_0015.jpg Projects To attach straps to the mask, I bought some bathing suit hooks. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482081042-YVCQTYLEKVFQ5NZRT9GS/Bushido_0016.jpg Projects Tacking the hooks in place, I poured a small amount of resin in the corners to lock them in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482083036-8BS5N88V6UDQ9MG1LYFW/Bushido_0017.jpg Projects A base coat of gloss grey. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482086683-RY59ET5WSW5SVFP10VZE/Bushido_0019.jpg Projects I painted the inside of both masks with flat acrylic black paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482086941-UIP1MINO16ZH71VYQ03F/Bushido_0020.jpg Projects After the red areas were painted, I applied a protective coat of matte finish Crystal Clear. The half mask here shows can see how much of a difference the matte finish makes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482090110-OR6CA2JG8LPMMTMIJSNT/Bushido_0022.jpg Projects The finished full mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1525482091882-AWFREV4RU7KRJ470146I/Bushido_0023.jpg Projects The finished half mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706060406-6C7YGLA3RDTL9MOTK95M/BaghNakhs-0001.jpg Projects I was commissioned to make a pair of bagh nakhs from the video game Final Fantasy XIV. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706072703-W6I8WZPTZ13UEM5DT78C/BaghNakhs-0002.jpg Projects I started with the claws, cutting a master from 1/4″ poplar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706075737-BJG6YP8XKQONLS3OU7SW/BaghNakhs-0003.jpg Projects I beveled the blade with the Dremel Sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706076190-9W19WCNQ4NK96S1464RH/BaghNakhs-0004.jpg Projects The top trim of the blade was made from strips of styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706080583-CXH4SYL44VNODB2ZLSYO/BaghNakhs-0005.jpg Projects The completed blade master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706080570-3AJKUQO69KCAE4OC9FD7/BaghNakhs-0006.jpg Projects I cut grip panels from poplar, rounded the edges on the belt sander and drilled holes for the rivets. I found large snap covers that were right size for the rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706084439-67T1BCDE1DVA7LGUPE20/BaghNakhs-0007.jpg Projects I used a threaded rod to connect the two poplar handles. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706085741-OLGEXHC5FFVU8KXBX030/BaghNakhs-0008.jpg Projects For the actual grips, I cut MDF with a channel for the threaded rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706096644-KUJ88DJUP3ZNOQUL2XG1/BaghNakhs-0009.jpg Projects I cut a piece of basswood for the box that holds the blades. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706097922-SWX26UXE9LL7WB02BG6M/BaghNakhs-0010.jpg Projects I drilled holes in the blade box so the handles could be connected by threaded rods. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706100830-QTT71VAOPY202ANLUOM2/BaghNakhs-0011.jpg Projects I cut a paper cutting guide from the plans to mark the opening for the blades and then used an exacto knife to start the hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706108696-J2T8U8VHIBIOT955326R/BaghNakhs-0012.jpg Projects I put a router bit in the drill press and started cutting material out of the blade hole, removing 1/4″ of material with every pass. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706127087-VP5RA4TJI26816ZTJ78W/BaghNakhs-0013.jpg Projects The bit only reached halfway, so I flipped it over and cut through from the other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706133495-IL605TYARU04HDLQFLD1/BaghNakhs-0014.jpg Projects I rounded the edges of the box with a router bit in my Dremel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706140066-9CDYZ4QT0V6D8XZ9KLJ1/BaghNakhs-0015.jpg Projects After sealing the basswood with shellac, I glued strips of styrene around the edges of the box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706143902-I3VPSKYBR1G17BD9L86R/BaghNakhs-0016.jpg Projects Just as soon as the glue set, I noticed a new detail in the reference photos…the ends of the box are actually cut short. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706145149-DZX4E0R9MVGSZV020TPD/BaghNakhs-0017.jpg Projects I re-cut the inner strips and glued them in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706149389-5TG2S15DMDYYL5PGZXCS/BaghNakhs-0018.jpg Projects Next I glued half round styrene strips to the outer edging. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706150661-IJSPEX69OGRB9AEYG2N6/BaghNakhs-0019.jpg Projects Then I carved channels inside the box for the panels that would hold the blades. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706153578-ITHUCQ75EPYTZA358DDZ/BaghNakhs-0020.jpg Projects I forgot the small strips on the ends of the grips so I made those out of thin styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706155362-AXRTPS9O9XWVLNAD9VJ1/BaghNakhs-0021.jpg Projects The assembled grip with threaded rods inserted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706156605-PO5YI6DCOE3ZY1WBQ76V/BaghNakhs-0022.jpg Projects To make the decorative rivets for the box, I cut airsoft pellets in half and glued them inside rubber O-rings. I assembled four, molded them and cast resin copies for the box master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706157341-IT6NI2NM6FBC4PV0KBYF/BaghNakhs-0023.jpg Projects Here is a resin copy of the crest that goes on top of each blade box. I made the original with different thicknesses of styrene and added nail heads for the rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706160022-QLWXKTM6TMYNQYKKSET5/BaghNakhs-0024.jpg Projects After a test fitting, I added some balsa to thicken the bottom of the blade master’s support. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706160546-UDFY3ANZTRXLUOCBJIVY/BaghNakhs-0025.jpg Projects I cast resin copies of the blade master to be used in the final props. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706170012-NZVWG8WE39M9LN54WPIK/BaghNakhs-0026.jpg Projects Here are some resin rivets to be glued on the master. I was pouring excess resin from other molds into the rivet mold so I wound up with far more than I needed. At least I could pick the best copies! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706170736-GR75659HO5YS177OP81O/BaghNakhs-0027.jpg Projects I constructed a MDF box to pour the mold for the blade box. First I filled the bottom with clay up to the center line of the blade box. Silicone was poured in this side first then, once it cured, the box is flipped over, clay removed and the other half of the mold is poured. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706175740-5HVOZUJLPXL7QSNH7C4J/BaghNakhs-0028.jpg Projects To make sure no air is trapped in the details, I poured resin in each side of the mold. Once that solidified, I joined the mold and poured the center. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706175738-UFSCA31TEBK1G927S34M/BaghNakhs-0029.jpg Projects A nice resin copy of the master! I had to clean up the seam line and putty up a few holes but that’s nothing compared to having to build another blade box from scratch. I was surprised that some pencil lines on the master got transferred to the resin by the silicone mold! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706182587-H94V7VGLVBGOLYY9BCSV/BaghNakhs-0030.jpg Projects To make the panels that hold the blades, I made a press using a MDF block in the shape of the blade box and a plaster mold of the block itself. The theory was to heat thick plastic with a heat gun and squish it into shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706181772-Z9QIQWI5PUEQZY3PAXMV/BaghNakhs-0031.jpg Projects The results of the press: Four identical plates! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706207218-3J3XFWETOQGY3U31S2CF/BaghNakhs-0032.jpg Projects The base paint coat for the blade box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706208433-VFCWB5SL3H8SS8B98CBS/BaghNakhs-0033.jpg Projects I hand painted the rivets on both boxes as masking would have been too difficult. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706212649-SYF96C9EUD48V7EEE3Z1/BaghNakhs-0034.jpg Projects The blades were painted with the glossy grey and the the top strip was masked off and painted gold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706212426-32VQ34K3VEUN6FO65RNR/BaghNakhs-0035.jpg Projects The handles were finally epoxied onto the blade boxes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706220649-6HMXSI1A24K8CB9NF1DE/BaghNakhs-0036.jpg Projects I slid the top plate through the slot in each blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706222166-5X1D3JQNMB5I0SVCU73U/BaghNakhs-0037.jpg Projects Holding the bottom plate in place, I slid the entire blade assembly into the blade box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706250713-41FTCT57XZHGC60ULN75/BaghNakhs-0038.jpg Projects The last few inches were very tight so I had to use a ratcheting clamp to get the blade assembly seated. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706250619-Z6GM63ZJ89GCI5FGZRT9/BaghNakhs-0039.jpg Projects The final bagh nakhs! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706269205-LAZDWN1L0QJG6MHHVLN6/BaghNakhs-0040.jpg Projects View from the back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706269502-P05Q61GT2QQQCCSI7FR5/BaghNakhs-0041.jpg Projects View of the business end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706273282-EQADNIV0I06I6JOLW0SK/BaghNakhs-0042.jpg Projects Detail of the blade box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1526706273515-6E5S8YOJDZ34BIYH4R4I/BaghNakhs-0043.jpg Projects Don’t scratch your ear when holding the bagh nakh! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140146471-9IAPED8VPVJGA4P2K4DT/FateSpear-0001.jpg Projects I was commissioned to build Gáe Bulg, Lancer’s spear from the anime Fate/Stay Night. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140146853-QW3WYR0QRB4PWMV3353R/FateSpear-0002.jpg Projects I started by lathing the head and tail shafts out of a single piece of basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140147228-WQMPEZSB4HWV2TKPMKCA/FateSpear-0003.jpg Projects Since the tail spike would be coming in contact with the ground and basswood is soft, I made the spike out of oak. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140148056-V4FWNDEYB0EAONT01KGB/FateSpear-0004.jpg Projects The spike is glued into a hole in the base of the tail piece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140148306-LG85RMYJZRP8J60ENZI3/FateSpear-0005.jpg Projects I cut out the blade and glued it into a notch in the head piece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140149300-1XLZJDYDN60FNG4TCU92/FateSpear-0006.jpg Projects The seam was puttied smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140149567-8K5SUPGHH05E785I3D7C/FateSpear-0007.jpg Projects A central spine for each side was formed from a 1/4″ wood dowel. It was sharpened to a point on the belt sander and then split in half. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140150574-SQYTMFJ78IGI8ER5IW8A/FateSpear-0008.jpg Projects Decorative discs were cut out of styrene and glued to the sides of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140150710-V1UEWI44ZCJ3OPVRET02/FateSpear-0009.jpg Projects I drilled each end of the main shaft dowel and fit thread inserts. This will allow a 1/4″ threaded rod to screw the head and tail pieces to the spear shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140152741-0WG6XLXAHSK8QA05KQAN/FateSpear-0010.jpg Projects I printed out a template for the shaft markings and transferred them to the dowel with carbon paper. I traced over the pencil with a Sharpie, correcting areas that didn’t look right. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140152568-URKC96SG4N0MXPXS5MA5/FateSpear-0011.jpg Projects I used puffy paint to apply the design to the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140154209-NNJYLSP4S20QDEBHI3S7/FateSpear-0012.jpg Projects The shaft has three circles on each side of the shaft.. I drilled out a hole and then glued a plastic disc to each. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140154355-CMX709H93NQ96MWXIXMH/FateSpear-0013.jpg Projects All parts received a base coat of metallic silver and then a top coat of metallic red automotive paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140155568-C7VFQES2QKWM1OSRXUS1/FateSpear-0014.jpg Projects The head and tail pieces painted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140155855-ZD5V5V77SMM2S287D6P8/FateSpear-0015.jpg Projects The parts disassemble for shipping. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527140156230-0EJ4ITTLPLT1GXLDPVTC/FateSpear-0016.jpg Projects The assembled spear is over six feet long. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227043299-ZQGNQZXIIF5B5Q6H74L3/redfield_old_01.jpg Projects I was commissioned to make Claire Redfield’s knife from the video game Resident Evil: The Darkside Chronicles. The final knife will be shipped to my friend Fevereon in Atlanta so she can make a sheath and shoulder holster for it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227043434-MHROKRPR8HLHNK6TN0BT/redfield_old_02.jpg Projects Because of the engraved logo on the blade, I decided to have the parts laser cut out of a compressed wood (very much like MDF) by friends at Scorpion Ridge Engraving. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227044422-TZCHM883BW53UK8UIALY/redfield_old_03.jpg Projects Here is a detail of the laser engraved logo. There’s just no way I could’ve done this by hand! Plus it’s identical on both sides of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227044666-OAP2F3K3G0LQESECLVYJ/redfield_old_04.jpg Projects The guard was also laser cut as a separate element. It fits perfectly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227045808-SI1NZXQI12QZ2B4XEGKO/redfield_old_05.jpg Projects The final component is the grip texture. I had the checkered pattern laser cut deeply out of the surface. I then used fine files to bevel each edge of the little squares so I wound up with a texture of fine, raised diamonds. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227045898-1A4051YCFMO63H681YW2/redfield_old_06.jpg Projects I then made a silicone mold of the grip segment so it could be duplicated in resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227047022-86WY3E8OSQY9TCOM3H9G/redfield_old_07.jpg Projects Here are all the pieces for one half of the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227047041-VJZ4AXCJUCL5BYI7Z5F2/redfield_old_08.jpg Projects For the insets between grip panels, I glued on 1/8” balsa strips. I also used the balsa to frame out the pommel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227047922-8GES3YBM9X6N63970IAQ/redfield_old_09.jpg Projects I shaped the insets before I added the grip panels….much easier that way. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227048026-S2BIOZJ9LSFKYVU7QKFX/redfield_old_10.jpg Projects The panels are a bit wide so I had to trim off a sliver on each side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227048850-QMPB8SFQVGBOMDB8754I/redfield_old_11.jpg Projects A quick test fit…everything works so far! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227049072-1KW2S6AC0P2Z7PAGHCKJ/redfield_old_12.jpg Projects I beveled the back side of the grip, glued them in place and then shaped the curved bevel of the other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227049739-NFT38F4LM773FFGTJXK6/redfield_old_13.jpg Projects I glopped Bondo into the pommel until it filled the framed area. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227049942-XUMPHI0GIOK568YS77Z7/redfield_old_14.jpg Projects The smooth sanded pommel half. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227051008-M3R39X7OW8EDXO98ZH8Q/redfield_old_15.jpg Projects I used the laser-scribed line as a guide to carve an edge on the blades. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227061531-59VH8EQHLD966M9UC3SZ/redfield_old_16.jpg Projects A test fit of two blade halves together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227062000-39M7AF3TYJTRHQOSRPZE/redfield_old_17.jpg Projects A coat of primer to clean up any small defects. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227063777-TIPS32UHXHCAFKE33NTA/redfield_old_20.jpg Projects I thinned a coat of Smooth-On Stroke to capture the fine detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227064234-R9HJ8KSXTIDIR2TF3MUS/redfield_old_21.jpg Projects A thick coat of Stroke to build the mold walls. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227064453-NS2KJDXVNGF618H5DPCS/redfield_old_22.jpg Projects After I made a support mold with Plasti-Paste, I pulled my masters out. The mold turned out super clean! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227069008-QR27JDAS8KG0TOELO0PU/redfield_old_23.jpg Projects I poured a small amount of resin into the mold and then added a thin steel rod for additional support. The guard also got a small steel bar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227069628-P3Q18B1ILSLY3PLXEU5T/redfield_old_24.jpg Projects The two halves glued together! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227070033-RZ97X683FP3I82KUJE97/redfield_old_25.jpg Projects I filled the seam and gave it a coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227070360-PB4L5YPMSVFP49NO0879/redfield_old_26.jpg Projects The final painted knife! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227070838-RO9KTZV79MRWW7OUP18Y/redfield_old_27.jpg Projects Detail shot of the grip https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527227071249-TUBTGLGVSCEV36K4QSCX/redfield_old_28.jpg Projects It’s a very comfortable knife to hold. Time to find a zombie to stab! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310946122-OPN3GAJI1E40QZJRWLPK/screw_old01.jpg Projects He is capable of attaching his head to various robotic bodies but I decided to stop at the neck. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310946382-M5QCQE2B96DP9VKQMMY9/screw_old02.jpg Projects After basing a 3D model on the animated character, I imported it into Pepakura and converted it into a paper model. I then printed it out and assembled it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310947831-NFZ7UIT1EE2OJKYPOI8G/screw_old03.jpg Projects I sealed the paper with a coat of fiberglass resin. The screw at the base of the neck would be made separately. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310948556-VGROHLC157F6C28VROAD/screw_old04.jpg Projects I slush cast several coats of plastic resin inside the paper until I had built up a wall thickness of 1/8”. The paper was sanded off and facets smoothed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310948674-VQ5H4DTMNLF8839W4NKQ/screw_old05.jpg Projects A further refinement of the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310949899-O3HYVI9TZKDEOBNIYDN9/screw_old06.jpg Projects I capped the neck with a disk of styrene and attached a cylinder of basswood to fit inside the screw shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310950114-FE8QNFQW7T5NL2AT5BSL/screw_old07.jpg Projects The plug socket for the back of his head was cut from 1/4” MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310950537-QHGFX7AQR4P0AJ8VM5KM/screw_old08.jpg Projects The shaft of the screw was made from a 2” ABS pipe. I lathed the end cap from a scrap of basswood. The paper model screw was assembled as a guide. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310950884-H7Z2W1BYWFMC8VAVHQJA/screw_old09.jpg Projects The end cap glued into place https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310951344-ACXC343RFNHR5H5H1KO0/screw_old10.jpg Projects Led astray by the paper model, I originally made the screw threads reversed. The correct threads were made by glueing styrene tabs to the pipe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310951632-ZGG35MBZNKCMDBOU4FCD/screw_old11.jpg Projects I built out the bevel of the threads with epoxy putty and then sanded it smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310952124-P75PGVMMO9CXNMGRTYZJ/screw_old12.jpg Projects The final painted Head standing on his stained display base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310952605-46H1I16PH3JLD29UUVJ1/screw_old13.jpg Projects Additional views. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310952930-0M6VG76L31L7RUSE0GC7/screw_old14.jpg Projects The secret of the stand…a nail is glued into the base that fits into a hole in the screw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311339074-1Q1JDUS5U2D122NK68X1/manjimaru_old_01.jpg Projects I was commissioned to make the sword and scabbard from this video game. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311338945-DWUP2AEQ2H1N0AL0C0Q2/manjimaru_old_02.jpg Projects I started by cutting the blade halves from 1/4″ poplar, cutting a channel inside each for a steel support rod and glueing the wood together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311340237-P1VFR5YTFVLRMBZPF6G7/manjimaru_old_03.jpg Projects I sanded an edge on the blade then sealed the wood with shellac. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311340255-J16LKVQJT4FAIFZI2C6S/manjimaru_old_04.jpg Projects I made the blade collar from black styrene plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311341605-6JYSLLWB6IY93J1655HB/manjimaru_old_05.jpg Projects I cut hilt halves from 3/4″ MDF, cutting a channel for the steel support rod and blade collar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311341697-8R5SR9EJOR4MR5SG2RPA/manjimaru_old_06.jpg Projects By the client’s request, I painted the blade red. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311342326-XS9WS0PCUH98Q37UI4Q2/manjimaru_old_07.jpg Projects I shaped the hilt using a Dremel sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311342571-1BANR5FL6L2TUJ1SL1CO/manjimaru_old_08.jpg Projects I made the scabbard out of MDF with 1/4″ poplar fins https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311343333-08XA1WLY4N5WHV12I9H2/manjimaru_old_09.jpg Projects I lined the scabbard with soft cloth to protect the finish on the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311343439-GK3FMGG6V5TEGNJUMBCA/manjimaru_old_10.jpg Projects I glued the scabbard closed and rounded the edges on the router table. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311344201-GOMB5IY38BZMXUKT8ARA/manjimaru_old_11.jpg Projects I carved some belly scales into the scabbard using chisels and utility knives. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311344430-LGNU8PMSJ0ZMBM7HVAGP/manjimaru_old_12.jpg Projects I cut channels for the steel support rod in MDF grip halves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311345190-TYU0E00Y8EY02PFCCVWE/manjimaru_old_13.jpg Projects I glued the grip parts together and carved out areas for the scale insets and gems. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311345414-489E1E4A114JIFFU80LK/manjimaru_old_14.jpg Projects I cut parts for the face out of 1/4″ and 1/8″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311346124-4SNOC9FKJ2IVJGCGWG2Y/manjimaru_old_16.jpg Projects The face parts glued on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311345910-WC2OTNQ1QJYKH2EM7EAG/manjimaru_old_15.jpg Projects I cut eyes from 1/4″ red acrylic that fit into the eye socket. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311346939-9ME0RDUGIY5FP15SLKKK/manjimaru_old_17.jpg Projects I puttied up the gaps between the face parts and the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311347039-4Z2OVRULAXVN88TX1Z7Q/manjimaru_old_18.jpg Projects I glued on 1/4″ antlers to the dragon’s head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311347747-AL71X9NTUCJEPU586VFR/manjimaru_old_19.jpg Projects I made stamps for scales out of hardboard and dowels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311347823-VW14DMSMVE2FJ0HHVYHE/manjimaru_old_20.jpg Projects I rolled out a long sheet of clay and stamped scales into the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311348872-LQKIBPSZBLQJJTZGLCG6/manjimaru_old_21.jpg Projects I poured plastic resin into the mold and removed a sheet of scales! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311349075-1VAC334G3CN1M0KV6NN7/manjimaru_old_22.jpg Projects I used a heat gun to soften the scale sheet to it would wrap around the dragon’s body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311349831-T0BP8WQD4STIMUTOPUUB/manjimaru_old_23.jpg Projects I used the same technique to cast resin whiskers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311350032-NER5O9XAC45RQWMUMFV4/manjimaru_old_24.jpg Projects The de-molded whiskers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311350952-3TWJNOSRNLOQP4OSB4CZ/manjimaru_old_25.jpg Projects I used a heat gun to soften each whisker and wrapped it around the body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311351133-YEOGE1D1CIKMWZ5EVWYU/manjimaru_old_26.jpg Projects I painted the scabbard with brass paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311352683-08XN2XYFFDITTSVCFS7T/manjimaru_old_27.jpg Projects I attached rings to the dragon’s back so it could be worn. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311352932-TOANVNTUW7IOZL2Y2MIN/manjimaru_old_28.jpg Projects I cast red resin gems for the pommel and grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311354484-GJATXWOJR9WOH5FTJQFZ/manjimaru_old_29.jpg Projects The final sword and scabbard! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311354902-RFZVZIOYORTYV6FSVS5H/manjimaru_old_30.jpg Projects The sword in the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527311355305-ZRAPMMBNJC4J6F9UDO18/manjimaru_thumb.jpg Projects Detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310821214-FSI5N9VWF7PG2YFXHTRZ/taki_old_29.jpg Projects I was commissioned to make Taki‘s swords Rekki Maru and Mekki Maru from the Soul Calibur video game. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310821279-YFL3BB503KMJG35ZYSG6/taki_old_30.jpg Projects I started by cutting grips from 1/4″ MDF, scribing lines across the surface of each. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310821782-63J2QN7GBPM9PR9312YN/taki_old_31.jpg Projects The blades were made from 1/4″ poplar. I beveled the edge of each blade on the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310821844-EUUKZSCETWDQGWG41YTI/taki_old_32.jpg Projects After the edge is cut, I shaped the points and finished the bevel on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310822342-T2ORPN5BPQXEWWFPF2HY/taki_old_33.jpg Projects The final sanded blades painted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310822437-2FYJ439LV130ZEZLG6U5/taki_old_34.jpg Projects I created many of the parts for these swords with a 3D printer from Shapeways. Since they charge by the amount of plastic used, I made each part hollow and in half. After some cleanup, I would make a mold and make resin copies for the final swords. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310823067-GIS1DNOO4RYHFZ3BOJUG/taki_old_35.jpg Projects To wrap the grips, I ordered tsuka-ito (the grip wrapping) from China. I had to order 150 feet although I only needed 11 feet for each grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310823167-RIF3TZ2RAC2UVAQNDNR1/taki_old_36.jpg Projects I cast two halves of the Mekki pommel and glued them together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310823845-EX03ZE7TRPLYZUVPWTKD/taki_old_38.jpg Projects The completed pommel for Rekki Maru. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310823506-QFLG1G1N8EIJP9GM2RBI/taki_old_37.jpg Projects The cast resin grip collars and decorative blade bases glued to each sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310824104-MIQG9X339MYYVNUGQMFB/taki_old_39.jpg Projects Once the blades were completed I could construct the scabbards for each. I made MDF boxes lined with soft cloth to protect the finish on the blades. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310827906-247X4Y65UI8K1HP17E6N/taki_old_42.jpg Projects I started to round the scabbards by making angled cuts on the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310828112-BCUWRWNMLCGC338X034V/taki_old_43.jpg Projects After the major cuts were done, I finished rounding them on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310824219-6UEDCJN0OGGDLLFWFTOV/taki_old_40.jpg Projects I forgot about the lion-shaped grommet for Rekki’s scabbard so I got a second package from Shapeways. The printed pieces arrive with a sandpaper-like texture that has to be smoothed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310826862-6024VPXX5LNM3BT2N92X/taki_old_41.jpg Projects The hollow back of the lion grommet. I will fill this with clay and cast the piece as solid resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310828323-OYB970ONI38E5UE3XZAI/taki_old_44.jpg Projects I glued the cast resin halves of the scabbard collars and bases together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310828667-DAFZDTNGSDX12M32FJ7A/taki_old_45.jpg Projects A quick test fit shows a nice snug fit! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310828770-KNZXZ4IAQFU7UBQUJKQ5/taki_old_46.jpg Projects I rounded the base of both scabbards to fit the new resin tips. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310829191-ZPFXFT1GL8915AOV9LRW/taki_old_47.jpg Projects I cut a plate from 1/4″ poplar for the back of Mekki’s scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310829275-X3SWM1Q1SGEX6R3LQFK1/taki_old_48.jpg Projects I blended the space between the scabbard and the back plate with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310829615-L3SNI49X1C565NKK0IVY/taki_old_49.jpg Projects I cut trim from thick styrene and heat formed it to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310831089-V0C6E35XRM6FL1DLS6XP/taki_old_54.jpg Projects I then applied epoxy putty to form the scroll work on the trim. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310829801-RZT5HVWE5CD92S1ZF5L3/taki_old_50.jpg Projects I used a link of plastic chain and a tube cut from a mechanical pencil for Mekki’s inset area. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310830117-OLUQI1KUTM91BX4V8K2V/taki_old_51.jpg Projects I vacuum formed a styrene cover plate for Mekki’s inset area. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310831246-O95RN3FE1TXC17PJW5AG/taki_old_55.jpg Projects I applied a border cut from thin styrene around the opening of the cover plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310830566-9Q15MKQXGZCRTD1U7ET6/taki_old_52.jpg Projects I cut thick styrene strips for the front and back of Mekki’s scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310830692-H039Z0R6WAQ1NC7VVMQT/taki_old_53.jpg Projects I painted Rekki’s scabbard with a base coat of white over grey and then applied a texture using plastic wrap dipped in white acrylic paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310831628-A3EWWWRAMLCG5QKO04BC/taki_old_56.jpg Projects I cut side plates from bass wood to border the inset area. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310831830-E0048VAFBO8N0VRHFZ1E/taki_old_57.jpg Projects I started shaping the side plates and carved the center to make trim. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310832077-698CC7MWMT4IRT5K9B15/taki_old_58.jpg Projects A coat of primer to see how everything is working together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310832182-8Y4QZW9QB4CA47VP9F5B/taki_old_59.jpg Projects I heat formed some final styrene details on the cover plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310832560-QI46L2XACZRB9FAFZAFP/taki_old_60.jpg Projects I found some ribbon of the proper width and color to wrap around the inset. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310832921-HJDJ9SDNCNX28GMXC14B/taki_old_61.jpg Projects I gave Mekki’s scabbard its paint job and applied the 3D printed symbol at the base of the cover plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310833408-T3RL6U1M23ON7MKCMBEZ/taki_old_63.jpg Projects To wear the swords, I used mirror rosettes and swivel rings attached to the back of the scabbards. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310833660-QDISN40AJD8TPG3QNWAE/taki_old_64.jpg Projects Hanging hardware attached to Mekki’s scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310833103-L9A7R829RWNUYPV9QPDC/taki_old_62.jpg Projects I wasn’t able to find gold ribbon in the proper width, texture and color make Rekki’s scabbard ribbon, so I found the closest match in size and texture and painted it with gold acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310833887-G516V4GE5ADTSWR8P1XU/taki_old_65.jpg Projects The ribbon applied to Rekki’s scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310834124-CVZ1GBU0SOLEMKN4NAVB/taki_old_66.jpg Projects The painted lion grommet attached to Rekki’s scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310834351-Y20QLCWCD5I9WTCX25QD/taki_old_67.jpg Projects I found a tutorial online for tsuka-maki (the Japanese method of wrapping sword handles) with tsuka-ito (the ribbon used to wrap it). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310834633-HHXU5BTONKQOU1K4336U/taki_old_68.jpg Projects The final wrapped grips. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310835059-4VMNHBL8280FXSMEXIXI/taki_old_69.jpg Projects Mekki’s scabbard features a magic scroll wrapped around the center. I printed both sides of the scroll and glued them to both sides of thin aluminum. The metal could then be bent to shape and tightly wrapped around the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310835150-QTNFCE8UN88NPABSRHIW/taki_old_70.jpg Projects The completed Mekki Maru! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310835520-AGKIJ34PBZZZ0QUZB233/taki_old_71.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310835635-SUX6BHGJGQ6M1VOOM67H/taki_old_72.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310836170-18LJMSEODJCCCUCQ3V3M/taki_old_73.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310836259-0M3XOHWJP3CO6OF00HEW/taki_old_74.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310837197-83SX1EBZFOH3T4YUT07N/taki_old_75.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310837406-G0RN6G5I6OGCFXQZFVTD/taki_old_76.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310838072-57NBHVCJDGEC5RW217UM/taki_old_77.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310838287-SAM4YCC44YPVB40IEX7Q/taki_old_78.jpg Projects The completed Rekki Maru! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310838650-UG81QDURL3EWFJC6X6RB/taki_old_79.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310838760-ZV01VLMIX5XEWHE864SM/taki_old_80.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310839412-L5RH2PB2SFP5MC4DD7QT/taki_old_81.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310839493-1GUZNERMY9KYBMTV3Y3H/taki_old_82.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310839866-1AT1J5OXMM9JM56DZFZQ/taki_old_83.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310558104-LTS4VJASNBD2F8NXWRUZ/interstella01.jpg Projects I was commissioned to make Shep’s helmet from the Daft Punk animated film Interstella 5555. The Helmet would need to have a working movable visor https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310558319-GJBGTOKEFYJB4F9D5XS3/interstella02.jpg Projects I started with a client supplied batting helmet so we knew it would fit the them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310560086-HYJPY32C3H9EATM8XP7I/interstella03.jpg Projects I removed all the interior padding so it could be transplanted into the final finished helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310560092-4KGW9ZKD43FLEE7VEA8H/interstella04.jpg Projects I cut off any geometry that didn’t conform to the final helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310561823-D5T47NF40VF3XEQ6QKXH/interstella05.jpg Projects I added sheet insulation foam to block out the new dimensions and used expanding foam to fill in the gaps. What a mess! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310561925-Q061KNWCHMAURMWUXWHN/interstella06.jpg Projects Once cured, I filed/cut/sanded the foam to the dimensions of my plans. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310562979-PYL956KV6VYKAZ710AOP/interstella07.jpg Projects I added Bondo to further shape the helmet, fill holes and coat the foam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310563261-NSGVVB2P2CU5VBE9YJMP/interstella08.jpg Projects I applied a coat of Bondo over the entire helmet to prep the final surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310563742-W1QNMM1HKZLLSC8VDPYL/interstella09.jpg Projects After much sanding and additional Bondo patches, a smooth suface starts to take shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310564162-TDC8IXFIU1RBYS2LC2NT/interstella10.jpg Projects Comparing the helmet to the plans, I noticed that the front profile wasn’t round enough on top, the side slightly slanting inward. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310564476-09P03Y36PE1IUZ12W1GC/interstella11.jpg Projects I added more Bondo to build out the sides and eventually smoothed it to a more accurate profile. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310564891-1VZMGKELP3XE4XBQZPPW/interstella12.jpg Projects From the front, I could see that the shape of the helmet wasn’t quite right. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310565195-LZ13EZ9QMI0LDY6766AG/interstella13.jpg Projects Additional Bondo rounded out the form. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310566765-ER400UGY9OGQ2LJLQ4QM/interstella16.jpg Projects I transferred the crest profile to poster board so I could see how it fit on the actual helmet. Once the pattern was adjusted to fit, I had a template to cut the crest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310568085-V5FJAJE9BKAL9ADSJW9L/interstella18.jpg Projects I cut the crest profile out of 3/4” MDF, and marked where it would need to be sanded to match the taper of the plans. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310568227-XGGM5JIKO2AESGIYT3QJ/interstella19.jpg Projects The final crest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310569800-7BF2PDP1B8FKB5M2YRM2/interstella20.jpg Projects To prevent the crest popping off during construction, I attached it with epoxy and screws from inside the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310570030-ETRT3ZJJTVKOUDNCMVUJ/interstella21.jpg Projects The final crest blended into the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310565578-F53BQS5O9QZ22W7WAMYA/interstella14.jpg Projects I formed the master for the ear cups from several pieces of MDF glued together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310565908-UXSPVK22IQ5P20RBQ6P6/interstella15.jpg Projects I decided to make the red semicircle on the ear cup raised to hide the slot for the visor. I heat formed .125” styrene over the cup base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310567073-BJTDKSEHNLGW796872Z2/interstella17.jpg Projects I used poster board templates of the ear cup to mark their placement on both sides of the helmet. This allowed me to match the location and rotation of the cups so that the helmet would be symmetrical. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310572075-P5EPGH1X5YFBYLY6LY5I/interstella24.jpg Projects I molded and made resin copies of the ear cups and glued them to each side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310571500-1JYI4JPZYTLVDV5TG1QN/interstella22.jpg Projects I needed half round styrene strips for the trim on the helmet, but no one made it thick enough. I cut thick styrene into strip and used a block of steel with the half round profile cut into it to shave the strips into shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310571203-176SY38EFU143BUKM9H7/interstella23.jpg Projects I glued the half round styrene around the border of the helmet. Thick styrene is hard to bend without distortion so I cut smaller pieces to make the tighter curves. After a coat of primer, I could smooth out any kinks or putty over any gaps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310572568-RS0IOAA0EXMF355NYG90/interstella25.jpg Projects Based on the angles that the visor would need move in both up and down positions, I cut a slot in the ear cups for the visor to picot through. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310573285-EBX4VHG4BN2N8XSJ5KBY/interstella26.jpg Projects I applied a thinned coating of Smooth-On MoldMax Stroke to capture the surface details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310573692-SLMSUWT7DGHML2L5PVYP/interstella27.jpg Projects After that cured I applied more Stroke layers to build up a thick mold wall. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310574424-UP2L1D3N6XQH1NODSIYK/interstella28.jpg Projects The next day, I applied a plaster mother mold in halves to the mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310575105-DZI41QPSY26MA3IRBZOH/interstella29.jpg Projects Once the plaster dried thoroughly, I was able to remove it and demold the helmet master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310575420-KB7U9O9ET3ENRA29WDNN/interstella30.jpg Projects The silicone mold was replaced in the mother mold so that it was ready for slush casting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310576309-ZVM5D7EUY3CFGHUMX02B/interstella31.jpg Projects I poured a small amount of Smooth-On 65D into the helmet and slushed it around until it hardened (usually in 3-5 minutes). I worked in sections and built up several coats to make a stable helmet shell. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310576400-XEF26M0JR3PDSPUATGOD/interstella32.jpg Projects The demolded resin helmet copy. The master sits behind it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310577978-6TQ518GC0F6VA4SB6EMB/interstella35.jpg Projects To make the visor, I placed the helmet master back on my plaster head and sculpted the visor lens as smoothly as I could. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310580833-HAUA57W29L1YP0I1YDZM/interstella41.jpg Projects To conserve silicone, I made a plaster waste mold of the lens. I sealed the plaster, applied mold release and used Bondo to make a copy of the lens sculpt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310581163-XHS9CQGBF5AF6OTOEJ35/interstella42.jpg Projects The Bondo lens was sanded smooth(er than the original sculpt), and glued to a wooden support. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310581786-A925NZ24VSAG2XAPHTKM/interstella43.jpg Projects The lens master was further smoothed until it was ready for vacuum forming. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310583195-3LXKTBZZ53QYJ2W2I8HW/interstella45.jpg Projects I bought my plastic, got set up to vacuum form it and my machine wouldn’t start! Rather than spend the afternoon disassembling and rebuilding the oven, I took the lens buck down to my local plastic supply/fabricators Plastifab and let them pull copies from 1/8” clear PETG. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310583005-I7KL5MHBSDLMTWC0O69O/interstella46.jpg Projects I rough cut one of the visors to check how it would fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310584397-5YEFM202LVGCUIHZ8UEW/interstella47.jpg Projects When I had the clear visor pulled, I also had them make an ABS copy that I could use as a sculpting form for the visor trim. I used clay to shape the visor and got it as smooth as I could (which isn’t very smooth, as you can see) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310584729-HNCH7GT6KHR2BX4UVXL8/interstella48.jpg Projects I made a silicone mold of the clay and cast a resin trim so that it could be smoothed and refined. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310588227-W2HIKBSJ8ZCPNY6PVD8L/interstella49.jpg Projects The resin trim test fit over the visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310589165-XN4FQJ22JJ4ANZG8AQBE/interstella50.jpg Projects I made a second mold of the trim and slush cast a hollow resin copy (to keep it light. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310589534-JFMPYKG4UHKKV9V2YY46/interstella51.jpg Projects Many glues will haze or melt clear plastics, so I secured the visor to the trim with screws. I glued in rare earth magnets at the top to allow the visor to stay up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310589903-DJ0GQ8Z6C9G6CCHTVYKF/interstella52.jpg Projects I drilled a hole inside the helmet for more magnets that would allow the visor to remain up. This is a test of that theory. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310591109-L7RJ40WV1JU3EMIJPA88/interstella53.jpg Projects To tint the visor, I bought a giant pot and dumped in several packets of RIT dye. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310591305-FGS7Z0XZ23WKS51WFKVJ/interstella54.jpg Projects I brought the water to 150º and immersed the visor into the dye. The heat allows the dye to get into the plastic’s surface but it’s not hot enough to melt or deform the PETG https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310592370-BN9YO4KYXOOR7MPQ8P3L/interstella56.jpg Projects The final dye job. The dye didn’t affect visibility at all! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310593591-GBCVHADU9ZJEU96GW78C/interstella57.jpg Projects The painted trim mounted to the visor https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310594037-GSDXRMH3V3L2NV769D51/interstella58.jpg Projects I hot glued the padding into the final helmet https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310594364-13KK84J8CM52H3FJVKKR/interstella59.jpg Projects The final painted helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310595017-KK4642RLU5RWDZFFVPHI/interstella60.jpg Projects With visor down https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310595138-BV4YIOWHRUGJF8UYR8JR/interstella61.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310595734-EWZR8DGHLD9H79LP77XG/interstella62.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1527310596021-6OSMQ3H1AGW47L5LJ6U1/interstella63.jpg Projects and from the back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698323099-8A16SA2LKWZGHCM7LMM8/goemon_old_01.jpg Projects I was commissioned to make Goemon’s kiseru, a traditional smooking pipe, from the Goemon video game series. At the client’s request, it would be 48″ long. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698323206-N8RDVP6U76SYMZ06YBB9/goemon_old_02.jpg Projects For the mouthpiece of the pipe, I was able to find a wooden finial the right size and checked it to my lathe for modification. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698323608-M42W65FETSH0X4H5DSHZ/goemon_old_03.jpg Projects Since the lathe was occupied, I attached a disk of MDF to a drum sander attachment spindle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698323752-2E5XD7KAZTINNPW63DWB/goemon_old_04.jpg Projects I was able to round the edges of the disk by spinning it with a hand drill and used sandpaper to shape the piece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698324058-69SRWRY38I342QUQFIOG/goemon_old_05.jpg Projects The finial’s ball was flattened slightly and I scribed a line for separating the ball portion. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698324156-Q9UAU4FBK1R6OAT4OB43/goemon_old_06.jpg Projects The finial ball and disk glued together over a threaded mounting rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698324549-34QTSFSP5CKRTEMCQRR9/goemon_old_07.jpg Projects The head of the pipe was constructed by glueing together many sheets of pine and shaping on the lathe. I cut off the top of the bowl so I could re-attach it to the lathe to hollow it out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698324686-XI5EG0W0DZIBXIR37FBZ/goemon_old_08.jpg Projects I flattened one side of the head to mount to the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698325022-Y7OKS237205NRQHQ3S19/goemon_old_09.jpg Projects I made a collar out of MDF on the lathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698325083-D4RPNRV9GZE0H5K9MCQO/goemon_old_10.jpg Projects I used a threaded rod and wooden dowels to attach the collar to the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698325393-4K3PYXNXEK7UG4JQBEW0/goemon_old_11.jpg Projects The collar attached to the head with the threaded rod exposed to attach to the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698325597-FT2OYRWCWXABNBIRI071/goemon_old_12.jpg Projects I used a 4″ x 4″ to make the shaft. Here I’m starting to knock off all the corners. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698325896-NR4TBQ7K3EMEBQZBUP02/goemon_old_13.jpg Projects The finished shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698326093-LULFSWU2G4517FXGFL4R/goemon_old_14.jpg Projects The mouthpiece attached to the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698326385-DWCUCVF8R6WR17S93HVR/goemon_old_15.jpg Projects I attached the rim of the bowl to the lathe and hollowed out a gentle bowl shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698326420-CM19JRKZM9K9TDET9555/goemon_old_16.jpg Projects The bowl rim re-attached to the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698326796-LAQC6U1SONTWZHU9ON8G/goemon_old_17.jpg Projects I forgot to make the hole in the mouthpiece so I had to drill it and hand smooth the edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698326898-CG568NZ4YNG1PU1F4JGM/goemon_old_18.jpg Projects The final painted pipe. I used a brush to apply the paint so the paint has a brushed metal appearance. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698672797-QNSTQ0D3A5M9VGKP4UR4/scythe_old_00.jpg Projects I was commissioned to make the “Artemis Rod” weapon from the anime series Vampire Knight. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698673113-OCB1TQJERG7Y23CW22S4/scythe_old_01.jpg Projects To make the long shaft, I lathed it in 2′ sections out of 1-1/4″ poplar dowel. A longer piece on the lathe just wiggled too much in the center to work. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698673729-V8DL31BLS708VL0BHLFZ/scythe_old_02.jpg Projects All the shaped segments in position. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698674006-HBAPMBRG8TY8N7WL0ZDF/scythe_old_03.jpg Projects My plan to connect them to each other was to run a threaded rod through the sections and string them like beads. I clamped my drill to a shelf and attached a long 1/4″ bit. I then carefully lowered each section onto the spinning bit, stopping occasionally to make sure it was still centered. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698674604-1Z2LXK4V9C4GC3HR56FZ/scythe_old_04.jpg Projects A quick test fit of the threaded rod. The end pieces leftover from lathing still have to be trimmed off. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698674692-L5K5YWY68A823H9WRVW5/scythe_old_05.jpg Projects Two major sections of shaft glued together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698675494-DQ7CVHR9G991GLUYCTIJ/scythe_old_06.jpg Projects I used Bondo to make the diamond pattern around each raised section of the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698675583-CXY4X4V7E6TAC8LZS0US/scythe_old_07.jpg Projects The blade was sculpted out of two sheets of blue insulation foam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698675980-N6PH4147IJZ3RD4OH8PM/scythe_old_08.jpg Projects I cut a piece of thick plastic to sandwich between the foam blade halves. This will reinforce the foam as well as act as a solid connection point for the shaft. A small section was lathed and then slotted to fit around the plastic. It was then epoxied and bolted in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698676159-41W7H8LLCB0ICDY4P2TX/scythe_old_09.jpg Projects The foam sides glued together around the plastic. For glue, I used a small amount of Styro Spray, the foam hard coating resin that would cover the sculpted blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698676988-S3LHP86BFT3VXVAA1HE8/scythe_old_10.jpg Projects To sculpt the blade I used a small rasp and sanding sponges to smooth the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698677083-MJ1U9YKIJTJA57HNSYDK/scythe_old_11.jpg Projects The final sculpted blade. I few coats of Styro Spray and some putty work at the shaft and it would be ready for painting! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698677514-53X7YGH19S9HCMGIZW2A/scythe_old_12.jpg Projects The final painted scythe. Although you can’t see it in the photos, I used hammered finish silver paint to enhance the weapon’s organic qualities. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528698677775-RLEKE1TG8TJ1BQ8JAM8R/scythe_old_13.jpg Projects Detail of the finished blade. Assembled, the Artemis Rod is over 7′ tall. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697799412-FPDGUW9IPRQQ2RJGFPOY/scouter01.jpg Projects I was commissioned to make the a Scouter from Dragon Ball Z. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697799520-K5D785DXAABKPC9RIBL9/scouter02.jpg Projects Since this item is worn over the ear, it needs to be light. I made MDF masters for the parts of the Scouter so they could be vacuum formed out of plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697800352-471HCO4GIHH53C7D2D2S/scouter03.jpg Projects A plastic body shell vacuum formed from the MDF master. I have a lot of webbing but I can clean up the corners so it’s not worth remaking. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697800659-MBWQDLCUXA6721327TS4/scouter04.jpg Projects The lens arm after vacuum forming beside the MDF master. The yellow splotches are just paint drops on the scrap plastic I selected. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697800957-EX0TP943BKTIPXZH6O12/scouter05.jpg Projects The vacuum formed bracket that will support the ear padding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697801366-442CF0ZCTH8JLVAPJ15V/scouter06.jpg Projects The padding bracket after it had been trimmed down for use. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697801684-8FNOKV0Z7SJJPTTXGSYL/scouter07.jpg Projects I filled the interior of the body and lens arm with blue insulation form. This supports the rather thin (.040″) plastic while adding very little weight. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697802222-XOR0FC7WWUHZ6QZZXZQ8/scouter08.jpg Projects I stole the vinyl covered padding from a set of cheap Harbor Freight hearing protectors. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697802433-OJVSG9GDS1IX3TNVRGIE/scouter09.jpg Projects A test fit of the padding attached to the bracket. Eventually I would glue down the edges of the vinyl to the top of the bracket. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697802744-9O029JAMKEFCYDL8J37L/scouter10.jpg Projects To attach the body to the padding assembly, I used the bracket itself to vacuum form a copy that would fit precisely over the bracket. I had to correct some warping that occurred to the bracket as a result of hot plastic pulled over it but it wasn’t too bad. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697802961-ASXA9HHBYY4L8AOVU7HO/scouter11.jpg Projects The new bottom of the body glued in place. The body now fits tightly into the hole of the padding bracket with no glue needed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697803067-38KXGTB1EY1QSGQD2KUK/scouter12.jpg Projects I assembled the Scouter parts and gave everything a coat of grey primer. I also cut red acrylic for the side pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697803334-8JY6KVSK7QRVNNZ7MYRW/scouter13.jpg Projects To attach the Scouter to the ear, I screwed an aluminum wire to the bottom of the body where it would stay hidden inside the padding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697804068-YKSA3N62GMLDML049H5U/scouter14.jpg Projects I cut the data lens from 1/8″ red acrylic. I heated the center with a heat gun and bent the lens over a MDF master covered with foil. I don’t know if the foil was necessary but I wanted to prevent the hot plastic from picking up any texture from bare MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697804024-028EFEP468P1CP5JP138/scouter15.jpg Projects A quick test fit of the lens inserted into a slot in the end of the arm. I left it unglued so the client could set it to a comfortable depth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697804532-QK8PI1JFU0P9MHAF05ZA/scouter16.jpg Projects To make the readout, I cut vinyl symbols to match a screen capture. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697804528-RWRSW72TKKR7AMZ7F3C4/scouter17.jpg Projects I backed the red acrylic buttons on the side with silver mylar to brighten their appearance. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697804971-RSKZ9A6I2IYEPXDQN65T/scouter18.jpg Projects The final assembled Scouter (after the body was painted with a glossy white). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697805323-P8F4MTX2JSRC1FREEJ7K/scouter19.jpg Projects The back of the Scouter. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697805448-2KPP2CBKKGFMW90OFAE7/scouter20.jpg Projects Me wearing the Scouter. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528697805839-4VF1376QDYXHHEXDSKSF/scouter21.jpg Projects Me in profile. Now I know how Lobot feels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955816968-B6DJ9PFFFO8S9MD9KP4V/bankai01.jpg Projects I was commissioned to build Soi Fon’s Bankai from the anime “Bleach”. Large builds are tricky…they have to be sturdy but light enough to wear. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955817466-E8B4DUGESJLQUY6HB8H5/bankai02.jpg Projects I started with a 6″ concrete casting cardboard tube. The client requested a 7′ length for the bankai instead of the 12′ length in the anime. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955820063-LHWLQ6MVHEX7XWFRHH7P/bankai03.jpg Projects For ease of transportation, the bankai will separate in two spots. The tubes join by inserting an inner sleeve made from thick styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955820850-I2853WU92C9MJBU4RHJD/bankai04.jpg Projects After cutting a hole for the arm to be inserted, I added a wooden dowel to act as a handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955822906-AHCUNP5G3A912NVMYXUR/bankai05.jpg Projects Because the tubes had seams and a rough texture that might not paint up that well, I covered them with .020 styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955824164-IGXJY4VB9A2B23YFU1IR/bankai06.jpg Projects The styrene gave me a smooth, even surface with only a minor seam along the bottom. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955826280-X7NY34PZMIS21GVGLSGS/bankai07.jpg Projects For the end cones, I glued sheets of MDF together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955827172-RADTLAKFAE0YTNRJBFU2/bankai08.jpg Projects I don’t trust a glue joint if it’s going on the lathe, so I bolted all the sheets together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955829596-GDYNUJ58IPY8VK3F2XEN/bankai09.jpg Projects The cone starts to take shape after some work on the lathe. I took the opportunity to fix some gaps with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955830366-XX44Y30E0HGIHFRDTPCZ/bankai10.jpg Projects After much putty and sanding, the nose cone is ready to remove from the lathe. The MDF pieces at the ends were removed and the rounded tip of the cone was shaped by hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955840338-6Z4CJAQQKMEUI59E8UJN/bankai15.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955833454-0M7SCD55SO3RQ5YXG8T4/bankai12.jpg Projects The face blast shield was made from heat-formed styrene in another tube to make the curved shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955836686-JXM1QQ02WIRZKI190NAX/bankai13.jpg Projects The inset was made by gluing in triangular pieces of styrene and puttying the seams smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955837151-92F5HZ0EZIAP9SSZFO7A/bankai14.jpg Projects The primered final mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955862341-WIXCLYUZHY084ABPRUCM/bankai27.jpg Projects The body shield was also made by heat forming thick styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955859642-YL6V5XFKW83SNTP39QZV/bankai25.jpg Projects To make the exhaust vents, I had to build a negative master for the inside of the vent. I framed up the shape with balsa, filled the recesses with foam, sanded them smooth and covered the whole thing in Bondo in preparation for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955840666-PZCG19RJJW4ZF3XBUDVO/bankai16.jpg Projects I brushed MoldMax Stroke silicone over the cone and vent masters. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955844659-J6YN4EWRECNPCETTRGSV/bankai17.jpg Projects The silicone was supported with a mother mold made from fiberglass-reinforced plaster. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955848186-NQ4EPIIP4F3FY5WXTCAU/bankai19.jpg Projects I slush cast a copy using SmoothCast 300 and it fit in the tube perfectly!. The surface looks uneven because dark tinted resin was used behind the thin initial coat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955875779-ZQ9TY2ZFG0LRTA169FZD/bankai34.jpg Projects The final vent 2-part mold with a plastic resin copy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955876836-U3696RXCSTUS2VEQK6H8/bankai35.jpg Projects I cut holes in the tubes for the exhaust vents. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955880677-WB5Z7TTM3Z97432HEU2M/bankai36.jpg Projects The resin vents were painted before installing them https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955880963-BO84QN0I3DG2A9RT78V6/bankai37.jpg Projects The vents were then hot glued into the tube sections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955851815-0WMHEFSNR19JHAENYWH4/bankai20.jpg Projects Both end cones attached to the tubes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955851908-8H5AL734CD0R50JCS3OY/bankai21.jpg Projects Both cone sections with a base coat of gold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955884231-5LAQOOL5HBDPMDWJFLWC/bankai38.jpg Projects The tubes were then given their distinctive accent stripes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955862655-7YHAJWHRB1SGCLJK50OY/bankai26.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955865605-E7HN4IL1M1TR61SZW2HZ/bankai28.jpg Projects To figure out the frame that holds to main tube, I cut a template from poster board. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955865998-MTZ3D9M9NYOB8G7D6XK7/bankai29.jpg Projects The design was then traced on to thick styrene and it was heat formed to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955869469-TBEMQYIKG4ALJAY94MTG/bankai30.jpg Projects To make the frame more durable, I bent aluminum bar stock to the proper profile. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955869703-BC8YJVJMW2JO06HCH2P3/bankai31.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955872678-DW0WKSXRPJGTI9SQKDRQ/bankai32.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955884663-3JU4JKTUZ7UQ10V1SUUG/bankai39.jpg Projects The final assembled bankai! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955889602-0RDO2XVKIPM1212Q8I4J/bankai40.jpg Projects The painted blast shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955894384-IIKHX2NCBIFNFEFJ9XN8/bankai42.jpg Projects Detail showing the exhaust vents. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955894880-GD79SC0T9VS5ZQ4WLB5U/bankai43.jpg Projects I decided reinforce the tube connections by drilling holes for three boles at each joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955899683-NW39PB1O9VLQ3NZ658P6/bankai44.jpg Projects The bankai can now be disassembled for easy transport. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955900349-ZK5XLMN111JPG50264JY/bankai45.jpg Projects The final bankai as worn by me. Even though this monster makes me look Hobbitty, I am actually 6 ft tall. The prop weighs 11 lbs but is nicely balanced when worn. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529082773047-KFGPXQIE3IHIS54UBXDX/18-bankai.jpg Projects The client with her bankai at ConnectiCon 2010. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955972918-7OE3FGUTD9J4EPQDA5H3/ergo_shotgun00.jpg Projects This is the main character’s shotgun from the series. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955973116-EK8G2TP62HB4CVPJ8OFV/ergo_shotgun01.jpg Projects I started by cutting the pistol grip halves from 1/2″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955973705-53VDPMHYBCC8UQY660C1/Ergo_Shotgun02.jpg Projects I wanted to be able to remove the trigger for painting so I cut the trigger guard in halves from 1/4″ poplar. The trigger in inserted from the top and pivots on a nail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955973892-K2XDS1V30V4QJG4FKVLD/Ergo_Shotgun03.jpg Projects I used a compression spring from a ballpoint pen to give the trigger its “pew pew pew”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955974206-LLCAUSZVPZW8VIQGSJGZ/ergo_shotgun04.jpg Projects I used a router to carve out a recess for the trigger assembly. It will be glued in after painting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955974500-UNSD5G0OMR10Z6M8OB5C/ergo_shotgun05.jpg Projects To make the grip plates, I used 1/4″ MDF to make a simple box around the pistol. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955975146-0VOS8QMSB8MC6S1CRPVA/ergo_shotgun06.jpg Projects I then routered the edges and sanded the grip to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955975407-0AO8XCQTE86358GITJ52/ergo_shotgun07.jpg Projects I lathed the upper barrel cowl from basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955975889-QWEF8RRAUDRR34ND9LUV/ergo_shotgun08.jpg Projects The pump grip was routered out of basswood as well. Half of the groove was puttied over to create the shotgun’s distinctive ridges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955976088-K9F8Q1L81PUQO6DEQQHV/ergo_shotgun09.jpg Projects I drilled out the center so that it could slide on a 5/8″ dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955976531-GM6MW70AT5AUFOHBWLLX/ergo_shotgun10.jpg Projects The bracket that holds the pump tube and barrel in place was made from two pieces of 1/4″ poplar glued together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955976902-LI6S6V9T4967CQNS4O65/ergo_shotgun11.jpg Projects This was my solution to make the pump spring forward. Rather than weaken the pump tube with some sort of internal spring configuration, I decided to hide the mechanism under the gun’s shroud. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955977223-0U84ULJDG6L8W4E4K041/ergo_shotgun12.jpg Projects The shroud was constructed from 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955977658-1G0ZR1HP8HRC36NSA3FF/ergo_shotgun13.jpg Projects The lanyard loop was made by bending 1/16″ steel wire to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955978116-KCTLUM9AIILX3OOJUX1Z/ergo_shotgun14.jpg Projects For the exposed barrel, I sanded the inside of PVC pipe so that it would slip over the barrel dowel on either side of the bracket. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955978951-XIL7L0TEX9UWKNY8LCJ4/ergo_shotgun16.jpg Projects The final shotgun. I used gloss black on the grips, dark grey on the shroud and Metalizer gun metal paint on the other parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955979221-4E3X4DGJDZWQFO3JFBEA/ergo_shotgun17.jpg Projects The lanyard loop can swivel out or lays flat against the butt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1528955979472-MKZB2YRMPI8RFJSWZ7MW/ergo_shotgun18.jpg Projects The business end! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529087634490-5XAEJ7FFC1TJ0S3B1WMY/mekleth_old01.jpg Projects I’ve been re-watching Star Trek: Deep Space Nine and decided to make Worf’s weapon, the Mek’leth. (Apparently, Worf got tired of hearing Jadzia’s endless Curzon stories. Join the club!) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529087634452-YHVXIC1EIJU28VMJWR2R/mekleth_old02.jpg Projects I started by cutting out the profile from a sheet of 1/4″ poplar. I used a Dremel tool to bevel the edges of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529087634948-1ZQK3GWBP81UVED4BAPG/mekleth_old03.jpg Projects Much putty and sanding refines the curves and bevels https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529087635000-JADDH8EH300ZCT9WPTK6/mekleth_old04.jpg Projects A base coat of silver. The grey square was where the clamps held it during painting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1529087635435-VJG6JGTJL4COUDFJRGB2/mekleth_old05.jpg Projects I used a thin stretchy vinyl to wrap the grip of the handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164680330-5HWYYH4NCZI0F2JEEF9F/sakura001.jpg Projects I was commissioned to make the “Sealing Wand” from the manga and anime series Card Captor Sakura (aka Cardcaptors). In the series, the Bird headed top changes to… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164680493-3XIQZXDBXI61FHGPTAVB/sakura002.jpg Projects …A star in a ring with tiny wings! Magic, folks! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164433499-U5GQ27KIKOQ9TJIGRPHD/sakura01.jpg Projects I built half of the star head in 3D, keeping a 1mm wall to save on printing costs at Shapeways. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164441021-ZT0ZNL87QTD3H4PXV0D3/sakura03.jpg Projects The base of the staff was modeled the same way. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164442045-FX0J3IPYSX5XV6DX8QQU/sakura04.jpg Projects I was unsuccessful in building a model for the bird head so I decided to make my master from MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164458188-C393WU0CZFA9U0730T3X/sakura05.jpg Projects I made the wings from 1/4″ MDF and carved out the layers of feathers with Dremel, chisels and blades. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164465617-P07R9AANDIPTYGD0J8N4/sakura07.jpg Projects The bird head sculpting finished and ready for smooth sanding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164498067-R1LAKDXBY2TBRHH8NPQF/sakura16.jpg Projects The staff was made from a 1″ oak dowel. I inserted a 1/2″ dowel in the end to attach the tip and flared both ends with Bondo, guided by a slightly larger MDF disc. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164506915-OWJOFBHE7XGXWJ3MTA1H/sakura18.jpg Projects I added a threaded insert so the interchangeable heads could be attached with a threaded rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164507061-2I3MHD4UYG1F0I95Q8IW/sakura19.jpg Projects The final staff ready for painting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164464921-SUFTIAKI8P9ETIFH8KFB/sakura08.jpg Projects To attach the wings to the head and make sure they were straight, I cut 1/4″ MDF discs that would fit in the eye socket. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164471565-PPHVCHM99AT8WWYXXKVP/sakura09.jpg Projects Half of the disc was glued to the back of the wing and half was glued into the eye socket. Together they make a tight, consistently angled fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164482161-83GVMLMF1RGYEZ12C4UN/sakura13.jpg Projects The eye trim was lathed from 1/4″ MDF checked to the drill press. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164489193-DG32EDEVNQGB1ID4S03S/sakura14.jpg Projects The eye trim is glued to each wing master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164474251-WYLOQEIQGWA0O50HY6WP/sakura10.jpg Projects The master for the eye gem was made by cutting off the tip of an old space shuttle model’s fuel tank. I knew there was a reason I kept this for 20 years! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164476374-2561JYYSI397GQ25BP5T/sakura11.jpg Projects The surface was sanded smooth in preparation for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164481826-F49DBHRB3WS2VQGT4QA5/sakura12.jpg Projects Resin gems with silver mylar glued to the back. The mylar brightens the appearance of the resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164489596-L7D3Z4SP3IHR8JW5XTW8/sakura15.jpg Projects A test fit of all the bird head components. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164498061-N3XKEL8RRVXM3HLRYT3U/sakura17.jpg Projects I made a mold of the staff tip half, made two resin copies and glued them together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164518532-24PSQIKL5YNHPJS1I02P/sakura22.jpg Projects The new master for the tip is ready for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164520003-AEPDALNPQL4X104N5SL8/sakura23.jpg Projects The star head mold and the first resin copy from it. There’s a few dents to putty up but overall pretty clean. I later made a new mold so I could get dent-free pristine copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164526443-HQM3JC5NZ9BDIWKDMEHQ/sakura25.jpg Projects Two halves of the star head glued together, seam filled and ready for painting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164530178-YC946E7JJ4D0JA0LM7HK/sakura26.jpg Projects Base coat of pink with white wings painted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164537097-2G79O4RYX8ODVEXSE5IH/sakura28.jpg Projects The final assembled star wand! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164532897-XY0SOWFYNADO0EFSWZ44/sakura27.jpg Projects Close-up of the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164544315-TURE6ZYRTI6198Y8FW4Q/sakura32.jpg Projects Final assembled bird head version. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530164542362-X09U33PL6QCWJ1STBNNX/sakura31.jpg Projects Closeup of the happy birdie. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336211094-J7WGRI7M0GLHDQOLR4CQ/ppsh_old_01.jpg Projects I’ve always loved the look of this gun so I have decided to try something ambitious by re-creating this one as accurately as possible. I plan to make it as functional as styrene plastic will allow. My web research has produced actual machinists diagrams of most of the parts of the gun. Others I will have to reverse-engineer from photos. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336211192-AEBK9X7VOKP2FZ220IW7/ppsh_old_02.jpg Projects I cut out the sides of the barrel shroud as individual panels and join them together like a box. I glued in a thin strip on the inside joints for support. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336211654-WID4COYP2K6R9P1Q22ZG/ppsh_old_03.jpg Projects I glued the sides on to the top piece (a “u” shape) and then glued in a barrel support and the muzzle end. Before I glued the bottom, I painted the inside as it would be next to impossible to paint it when completed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336211793-JSZRS3IZAV0JCSCLPW08/ppsh_old_04.jpg Projects The lower receiver came together pretty fast so I don’t have any progress photos. It’s built like a box, the hardest part was the curved section at the back. I bent some heated plastic around a bottle with the right diameter and then glued it to the rest of the box. The big notch is where the drum magazine fits. Most of the rest of it will be inside the wooden stock. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336212187-F7POBU0MSO4L682P5HCB/ppsh_old_05.jpg Projects The breach block was formed by sandwiching a bunch of 3mm styrene sheets together. The other piece is the latch that locks the upper receiver down to the lower receiver. I heated a sheet of plastic with the heat gun, stretched it over the wooden form. I then cut a long rectangular slot out of the top and attached a small piece of plastic that I heat bent around a pencil. This area will house a compression spring that keeps the latch closed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336212291-AWV3ZFDTJ3S4LSV3ED8S/ppsh_old_06.jpg Projects A “L” shaped piece was glued on to the end that will fit into a slot on the lower receiver. Note the spring in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336212737-HOPQLPTAHBISGL534IGR/ppsh_old_07.jpg Projects On the REAL receiver, a small “U” shape is cut into the top and the metal is bent up to form a catch for the spring. Since it would be extremely difficult to replicate this with the plastic, I just cut a piece and glued it on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336212837-OAWI1XLNJDXWGDO8LYQX/ppsh_old_08.jpg Projects The completed latch! You can see the slot where the tab is inserted on the lower receiver. The white dot on the side of the latch is a pin that goes all the way through both the latch and Upper receiver. The pin actually runs in a small slot on the receiver that allows it to move back and forth about 1/4″…enough for the latch to disengage. The upper receiver swings freely to access the internal mechanisms to come. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336213400-6FOKOLET78HHT2GH3QK7/ppsh_old_09.jpg Projects You can see how the upper receiver latch locks into a notch on the lower receiver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336213474-SFUO6PYS5XJ44648TAS6/ppsh_old_10.jpg Projects Using a cutaway poster as a guide, I built the trigger assembly internal parts and the rear sight. The rear sight is pretty clever as it uses an inverted “v”-shaped piece of metal as a rocker spring to toggle two different sight apertures. At this point, I wasn’t completely sure what these parts did or fit together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336213796-KYC587505KMY48GUP0Y5/ppsh_old_11.jpg Projects The spring guide is a rod that acts as a guide for the bolt as it moves in the receiver. I used a long bolt, trimmed down the head with a grinder, and sheathed it with an aluminum tube. The bolt is pushed backward by recoil and hits a plastic stopper. For this I used laminated plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336214076-KP1YTEN7GYO4HAUCEI0B/ppsh_old_12.jpg Projects The bolt pulls rounds out of the magazine, pushes them in the breach and fires them. The metal strip on top is the extractor spring which I made out of metal from a picture frame. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336214249-Y19DA4FIHCEJDN04YA4F/ppsh_old_13.jpg Projects This was made by laminating some 20-odd sheets of plastic together. Now it is a SOLID hunk of plastic! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336214605-DB5Q3DR7DX9J2Z3BD5FW/ppsh_old_14.jpg Projects Another view of the bolt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336214820-CQ7IVU0KHFZNN68GNGUB/ppsh_old_15.jpg Projects The bolt slides on the spring guide as shown. A spring will fit between the bolt and the brown piece to move the bolt forward. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336214986-M2GS3L9MQF1F08KMLC76/ppsh_old_16.jpg Projects The firing pin fits in the bolt face. For this I cut off a piece from a toy, put it in my hand drill and used a blade to lathe the tip. This piece is only 1/2″ long. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336215378-M1LMEIYLPTZDIIL4HHF2/ppsh_old_17.jpg Projects When it’s inserted, another pin locks it in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336215520-KUK4IURZLWTK1GVATJBY/ppsh_old_18.jpg Projects The safety on the PPSh-41 is a small sliding latch that locks the bolt in an open or closed position. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336215799-L5T65BDSH0AS48AP6BTN/ppsh_old_19.jpg Projects It utilizes a small spring powered plunger to lock it in place. I had trouble finding a spring that small so I cut off a small piece of a rubber octopus’s tentacle to push the plunger. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336216056-CCC97TMFKXMZL8A15ICM/ppsh_old_20.jpg Projects The switch slides into a slot on the bolt arm and locks into two positions. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336216209-QBZEREANBULN070LAMYD/ppsh_old_21.jpg Projects After I marked the positions of the bolt in the receiver, I drilled, filed and cut the hole for the handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336216536-HDF3LZB9Q6ANQFOPJBD1/ppsh_old_22.jpg Projects Once I glued it in place, a little sanding made it appear to be one piece. The handle is surprisingly solid although the spring I’m trying to find shouldn’t cause that much torque. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336216782-Y3XUN4SXBHEUAMUHI51Q/ppsh_old_23.jpg Projects The selector switch (allowing either semi or full-auto fire) was a bit of a mystery for me. All I had to go by were some long shots and a cutaway drawing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336217070-98GT68J7IDVGGDUOLHMV/ppsh_old_24.jpg Projects Assembled I think it’s close…the actual construction is my best guess. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336217154-6KG075Z3H6PGZ8E97GDF/ppsh_old_25.jpg Projects The trigger assembly involved much trial and error. I barely understand the mechanisms but everything seems to work! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336217726-LAL1K8N0P35WGOGIRS7H/ppsh_old_27.jpg Projects There isn’t any extra space in the trigger box so everything had to fit just right. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336217622-5ASJ50555FKYKXKJ3YK0/ppsh_old_26.jpg Projects Even though it’s only plastic, everything seems to function. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336218060-4CZ9542QIXPT7VWGALZD/ppsh_old_28.jpg Projects The magazine latch was tricky to figure out but was in fact brilliantly simple in design. You can see a mis-drilled hole when I was trying to figure out the correct position. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336218111-OATS6UGSQMVNIJSRUERZ/ppsh_old_29.jpg Projects The latch in position shows how the latch rotates and, with pressure from a hidden spring, locks the magazine in place. The folding handle flips down and then moves the latch away from the magazine, allowing it to be removed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336218447-XSL58T2VHZ3G21HSSK6J/ppsh_old_30.jpg Projects The front sight came together very fast (about 1 hour) so I forgot to take pictures along the way. I didn’t have any good reference for the sight post so I modeled it after the front sight off the AK-47. The flat part is laminated styrene with a hole drilled for the post. The ring was heated plastic stretched around a bottle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336218579-M6EE5TGTKATZRRTJOWTK/ppsh_old_31.jpg Projects Here are all the parts I have completed in relative position to each other. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336218908-330L6Z9IIKJ97J1ZDYWC/ppsh_old_32.jpg Projects I found a plastic tube with the right outer dimension for the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336219033-01WGFK8IHD32LINPEW9T/ppsh_old_33.jpg Projects I dummied up a bullet from another kit with the same caliber. I cut down the AK 7.62 x 39 to become the 7.62 x 25. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336219398-IZRXDHPCC7EERHISCYYK/ppsh_old_34.jpg Projects The dummy bullet that I made fits snugly in the breach. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336219653-LONG9MHDBOISBCXXIIZF/ppsh_old_35.jpg Projects All the parts for the barrel assembly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336219788-8581WYR92TJU1I9ZS8FM/ppsh_old_36.jpg Projects After making a magazine that was too large for the opening, I was able to use it as a form for the new one. Using a heat gun I was able to press the grooves directly into the surface of the top and bottom of the new magazine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336220035-LSAE77ZBOLX55VQVQMQU/ppsh_old_37.jpg Projects For the side of the drum, I used a plastic jug as the form and pressed the groove directly into that. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336220145-BN3I9D6O8UN3J3DG41TV/ppsh_old_38.jpg Projects More putty to hide the seams on the assembled magazine. It didn’t turn out as crisp and machined as I would’ve liked but I figure once painted and weathered it will look like it’s been in a few battles! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336220454-16MQNV4518Q3EGKKBK0P/ppsh_old_39.jpg Projects The bracket will mount over the drum opening and allow the bullets to feed into the gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336220546-XT5DNJJIJB5M6YE0WBN4/ppsh_old_40.jpg Projects The center pin has a ratchet cap that holds the lid in place as well as allows the center spring to be wound. This was drill-lathed out of laminated plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336220992-VIA78461FY36TXF2OVXM/ppsh_old_41.jpg Projects Inside the magazine is a track that feed the rounds into the gun. I was even able to heat form a groove in the track itself…just like the real one! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336221136-PNHHC8MY20U7XZJOGQX5/ppsh_old_42.jpg Projects This scoop is inside the opening of the magazine and guides the bullets out of the track. It was also (carefully) heat-formed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336221493-0SMUZ12Z1AXZ73FVE533/ppsh_old_43.jpg Projects This swiveling roller arm attaches to the spring case to push the bullets out of the drum. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336221705-8PFZ0K2I329U3GA0O4L6/ppsh_old_44.jpg Projects The roller arm attaches the spring case that sits in the middle of the track. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336221838-RLEKGJGNN1UBAR53NRA2/ppsh_old_45.jpg Projects You can see how the clockwise rotating pusher arm runs through the tracks to feed ammo. Remember, I had no plans for the interior and it all had to be reverse engineered using cutaway drawings and photos. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336222240-1JVWLDEN389V9JVNBALA/ppsh_old_46.jpg Projects I originally intended to make the stock out of birch like the real gun, but pine proved to be more economical. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336222433-P7YBJA7NGYGSXTSY1OIO/ppsh_old_47.jpg Projects Since I intended to router out the butt compartment and the slot for the receiver in front, I made the stock from two pieces of 3/4″ pine, later to be glued together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336222815-9GJVP2MR3QI4L752VH6S/ppsh_old_48.jpg Projects Even though I built everything to spec, because of my materials the receiver had to be thicker walled. In other words, the receiver wouldn’t fit! I used some 1/8″ basswood to widen the receiver opening and then laminated all the parts together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336222928-ZD1WGDYBRVWFM5X6RVCW/ppsh_old_49.jpg Projects Then, with the assistance of my trusty wood plane, I carved the rough shape of the stock’s contours. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336223715-N3NGE1V3S0F2UMSUFUWD/ppsh_old_50.jpg Projects I had to dremel out a notch above and below the grip to mount the trigger assembly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336223810-1Y1PMA3GD9V49VGSXU32/ppsh_old_51.jpg Projects The lower receiver in place. A bolt passes through the tongue on both receiver and trigger assembly, locking them into the stock. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336224351-WSOLTG75SBK5EZU409CO/ppsh_old_52.jpg Projects The left side of the stock houses the rear sling bracket. I dremeled out this area to match a styrene bracket I had cut. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336224354-UE6PXX568PCUK5D6FB2Q/ppsh_old_53.jpg Projects I inset the butt of the stock to accept the butt plate. I used the stock to heat form the sides of the butt plate out of styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336224993-V27F7MPB4KVXE5NX4OWM/ppsh_old_54.jpg Projects I used a loop of wire to join the ends of the styrene in place while the glue dried and glued the end of the butt plate to the sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336225130-GH8E809ASOYARVIPFB75/ppsh_old_55.jpg Projects The edges were sanded off and smoothed and the screw holes were beveled. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336225641-3XDP87588JZOAVGHRY5O/ppsh_old_56.jpg Projects I glued in a small lip on the inside of the hatch and used a nail as a pin for the hinge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336225747-YNPHUXATBXXV9HVAAMEQ/ppsh_old_57.jpg Projects With no reference for the inside of the butt plate, I used a piece of steel as a spring to keep the door under tension. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336226191-R466MEPEN07OR5FQ7ANH/ppsh_old_58.jpg Projects The last thing to do was to stain and shellac the stock. Here are the final photos of this exhausting project! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336226416-HMDDMKCIHBH36HJ5V88V/ppsh_old_59.jpg Projects This gun can be disassembled just like the real one…nothing is glued that shouldn’t be. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530336226539-P1JSZPDU5J1XIJK7EKKW/ppsh_old_60.jpg Projects Eventually I will buy brass for the magazine and cast plastic bullets to fill the magazine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510877268-V2DRNCNBX2YZ3IZVF3GJ/paracelsus_old_00.jpg Projects I was commissioned to create Paracelsus, an ancient relic in the form of a key in the game Guilty Gear. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510877364-TFQASDEDXH0B7DI9TSLA/paracelsus_old_01.jpg Projects After scaling the plans, I selected a 4″ ABS pipe to use as the shaft. Since the prop will be large, I’ll be making it to disassemble for transportation. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510877813-IVLSV2L9PI5JVYQUOWMZ/paracelsus_old_02.jpg Projects I cut sections of pipe to use as connectors for the parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510877944-D240CGDKN2C7ZJ2RXRQP/paracelsus_old_03.jpg Projects I cut out a section of the pipe so it will fit inside the shaft sections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510878316-4PJ6RDX1D1UC0XDJO6O7/paracelsus_old_04.jpg Projects I heated the connector to narrow the diameter of the ABS. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510878429-8H6UF0LHX0TO3W9RKDFR/paracelsus_old_05.jpg Projects The collar is 6″ in diameter so I cut off a section of a 4-way ABS connector. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510878857-7RQ7UDRI5S7WQFZXNKOJ/paracelsus_old_06.jpg Projects I cut end caps out of styrene leaving a hole to fit the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510878915-CV0JCZ97AI8X3Z8BF001/paracelsus_old_07.jpg Projects I glued on the base and inserted a thin styrene sheet to form the interior wall. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510879363-NEDVLIDBO854XHFT66AA/paracelsus_old_08.jpg Projects I drilled a hole for a u-bolt, inserting brass tubes to protect the threads. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510879465-VDYZRGKUBZGPZF8486KM/paracelsus_old_09.jpg Projects I filled the interior with urethane expanding foam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510879860-LJXYMKLHQY2AUVQ5VION/paracelsus_old_10.jpg Projects I glued on the top end cap and painted a coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510879948-STF08RPLE2Z9MYYY0GN8/paracelsus_old_11.jpg Projects The final painted collar on the neck portion of the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510880265-NV2I9NCEVSKTRHFQZIUK/paracelsus_old_12.jpg Projects A smaller collar is located at the top of the lower shaft. I cut a section of the shaft pipe and heated it to expand it. I cut out another section to fill the gap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510880414-XLB21FZVZFESUUD1NEGF/paracelsus_old_13.jpg Projects I wanted the eyes to be hemispheres so I cut a template of the proper diameter and marked off a section on a plastic light globe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510880709-BUTRFMPTR2196LDKVW0M/paracelsus_old_14.jpg Projects I was able to cut 3 domes from the globe…two for the eyes, one in case I messed up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510881076-D6XPH2P4B6JSK4GAX6Y4/paracelsus_old_15.jpg Projects To make the eyes rotate, I cut discs from styrene and attached them in the center with a screw post. They would eventually be glued into a styrene base attached to the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510881231-JXJ1M58WG9AZMMEVKLAL/paracelsus_old_16.jpg Projects The eyes test fit to the color plans. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510881596-ZPJBY3F7ZCCNPO27XRNW/paracelsus_old_17.jpg Projects I cut a section of pipe to be embedded in the head. I flattened two sides to glue to the front and back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510881683-JMMXROS2L6KZ04J4RO7J/paracelsus_old_18.jpg Projects I glued styrene sides to the head styrene disc. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510881955-Q037A3K29HKJM7G4D3UL/paracelsus_old_19.jpg Projects I cut out the nostrils and used putty to create depressions. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510882175-4VGRJEL07C5IVJN2SAUG/paracelsus_old_20.jpg Projects I filled the interior of the head with expanding foam and glued the head disc closed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510882400-69XLPODCENSM5Y0QI9U7/paracelsus_old_21.jpg Projects For the bit (the business end of any key) I cut profiles out of 1″ blue insulation foam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510882701-F1B1H73VR6NJU4C30G6X/paracelsus_old_22.jpg Projects I split each piece in half in preparation to be glued. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510882904-A7SOYBKQAKQNTEAWWRED/paracelsus_old_23.jpg Projects I cut a piece of masonite and attached it to the pipe with threaded rods. This will support the foam and allow it to be secured to the pipe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510883283-5QN4JDGI6Y4BNXJSSG0O/paracelsus_old_24.jpg Projects I glued all the pieces for one half together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510883366-5UJK36NQ8WKZX60J6MY8/paracelsus_old_25.jpg Projects Once both sides were done, I glued them to the masonite. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510883742-G8V0PCDBOC29GN3M2AYZ/paracelsus_old_26.jpg Projects I cut out the hole in the bit, leaving a section at the edge for support. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510883862-WFH7K1FEJP0MFRPX9GO9/paracelsus_old_27.jpg Projects I covered the foam with 1/8″ thick ABS plastic. This plastic is thin enough to be light but thick enough so that any undulation in the foam doesn’t show through. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510884300-IV17LHQP04VUDAMKOZGV/paracelsus_old_28.jpg Projects The cleaned up bit attached and glued to the pipe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510884405-2KN4CGLA18VXROMTYMWY/paracelsus_old_29.jpg Projects I cut thin styrene for the face pattern. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510884790-KTWBPVT0V9SGUWMMYV23/paracelsus_old_30.jpg Projects I painted the head and attached the face pattern to it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510884894-PHFFHDZYHHW6G8Z3Z7CF/paracelsus_old_31.jpg Projects The eyes glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510885291-3818SRUSD7AAQ7IY0564/paracelsus_old_32.jpg Projects I used 1/2″ thick upholstery edging for the stitches. To keep them from unraveling, I taped the edges and applied hot glue to the ends. The ends were then tucked into 3/8″ hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510885468-3JAGCO57IZ6IQDUBOIR7/paracelsus_old_33.jpg Projects The final assembled Paracelsus. The movable eyes are fun to play with! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510885821-WSNSC8GP18XLU63VJH4S/paracelsus_old_34.jpg Projects Detail of the finished bit. I’m using a plastic chain from a parrot cage supplier. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510885971-4TTWTRUX00STDM8HH7RU/paracelsus_old_35.jpg Projects The u-bolt can slide out to remove the chain. It can be secured inside the neck with nuts but the threads keep it in place just fine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510886362-QI4VQ4UF2VEXUAZP2YXG/paracelsus_old_36.jpg Projects Detail of the finished head.The assembled key is over 7 feet tall and only weighs 25 lbs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530510886930-HFEH1E1W9WSH388NS6RJ/paracelsus_old_37.jpg Projects The client Bunnie-Fu with Paracelsus at MegaCon 2010 in Orlando. She’s 5’11” and is still dwarfed by this giant! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512103164-WONA8TV6Y8O06A7N8JS4/sunlight01.jpg Projects I was commissioned to build Kazuki’s weapon from the anime Buso Renkin. I constructed a 3D model in Strata 3D to work out dimensions and proportions. With unusual geometry like this, it was very helpful in understanding how this thing is made. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512108595-MN3M7WPY6SU5UOT2YJL9/sunlight02.jpg Projects The shaft was too thin to embed a steel core so I started with 3/4″ maple for strength and rigidity. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512109159-FRSQ8EW1E7KJ0E28R1R6/sunlight03.jpg Projects The grip widens near the head so I needed to lathe wood that would merge with the shaft. I cut a channel for a temporary maple shaft in two pieces of bass wood, bolted them together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512116739-R03EFA7QGLV0H40HO6JV/sunlight07.jpg Projects I used a Dremel sander to shape the transition to the square shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512120812-VEAT9IL4HH6O4KJ7JN5Q/sunlight09.jpg Projects I used the same method to turn the three rings and then attached it to the shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512112425-504HJPWYDONW6XW3D66Z/sunlight04.jpg Projects I inserted a threaded rod into the end of the shaft to hold the tail parts. The arrowhead was cut from a solid piece of maple, the ball is a wooden drawer handle and the part under it was turned from dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512113037-PA2IE9FSGETCOPDWNIF1/sunlight05.jpg Projects The arrowhead inserts were made from scraps of maple. The tail spike couldn’t be glued to the shaft until these pieces were in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512116536-KOBOXYO8CTMPUWN497RC/sunlight06.jpg Projects Before I attached it, I cut the details and panel lines into the arrowhead. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512124829-TIE6RS2VXTW3OJZAD17W/sunlight10.jpg Projects I cut the tail details from thin styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512120714-2WNLOKIE8MEI68SX3JD1/sunlight08.jpg Projects I used a Dremel sander to shape the transition to the square shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512124325-E1A2GQEUWVG39HBDMUBC/sunlight11.jpg Projects I filled small imprecations with spot filler putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512129046-WGBRHM4K8ZQBY07GMGX9/sunlight13.jpg Projects The final shaft. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512128042-N0BUHQCA6LH8O7C4WWEF/sunlight12.jpg Projects The recessed areas on the lance head were made from styrene. I used Pepakura to work out the geometry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512133982-MOP86PZFGK58UPUT5PDN/sunlight14.jpg Projects I cut the profile of the head from a thick sheet of styrene and cut a channel for the shaft to fit into. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512137777-8RV71DFU1X58IA5UDJM7/sunlight16.jpg Projects I then used styrene to lock a flattened area of the shaft into place. The shaft will be removable for shipping. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512134304-VT6BK71SKF54FH3STJ8Z/sunlight15.jpg Projects I cut the recess polygons from 1/4″ MDF and used styrene to make the diamond details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512138061-XCDERC62E9RJWVE4RYC9/sunlight17.jpg Projects After the polygons were made, it became obvious that the recesses were too deep. I re-made both sides to the proper depth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512142077-YFVXWKGKTNFTEU0WOR29/sunlight18.jpg Projects I attached the recesses for both sides to the profile. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512146898-ETYDT02X0Q9IKLJFEGHI/sunlight20.jpg Projects I glued styrene side panels to the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512147051-PIV2Q6N6FC2DNKF8IRYJ/sunlight21.jpg Projects I filled the interior with expanding foam to support the geometry while keeping it light. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512151919-7EEYS9J7UNA3TE4N0JJS/sunlight22.jpg Projects The cured foam can be carved to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512152232-C10ZSY6QWS6QDDPGA49X/sunlight23.jpg Projects I covered the exposed foam with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512155933-Y0AXYG10WS48AIFFH4BE/sunlight24.jpg Projects More Bondo to form the tip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512159940-1DC1R8QUJM86TQ2Q95O5/sunlight27.jpg Projects After looking at the reference material, I discovered that the tip need a knife edge rather than the point I had. I added Bondo to build up some thickness and then sanded a proper knife edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512164370-5TE08SPGZWFSP0QXFW5P/sunlight29.jpg Projects After all the minor seams and flaws were filled, I painted the head with a base coat of silver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512168060-T9F4KMEOIN3PC9JPAI7D/sunlight30.jpg Projects I masked and painted the color areas of the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512168162-T6UKGPR2IZOVHPUHGP83/sunlight31.jpg Projects I cut the zig-zag detail from thick styrene and glued them into the recesses. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512171669-3GCJDIVC3GHEORR5TF66/sunlight32.jpg Projects For some reason the polygons at the other end no longer fit after the orange areas were glued in. I would have to remove 1/8″ from each edge to make them fit properly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512176539-CM1119X7CVH43IBVPGD7/sunlight34.jpg Projects The final assembled lance. It is over 5 feet long. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512172712-AI6VGKMQ4CGIZRXSUS5W/sunlight33.jpg Projects It ships disassembled and will be glued together by the client. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512177178-WZMU2I5587PG7670SD94/sunlight35.jpg Projects Detail of the finished tail spike. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512416069-MC90S99SOFGP23RKE33A/witchking_old00.jpg Projects I saw some interesting tutorials on making props and costumes with hot glue and cardboard so I decided to try it out. The Witchking Helm has been on my build list for a long time and its simple shapes seemed doable in cardboard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512416359-WRPLTIEQZ4BLQ45D8T21/witchking_old01.jpg Projects I cut the cardboard layers and hot glued them together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512417235-QJUCL0EODEC6LEV9CZX9/witchking_old02.jpg Projects I used wooden dowels sharpened on the belt sander to make the spikes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512417972-T6IQZ4AW37W4C1OOHEH6/witchking_old03.jpg Projects I covered the cardboard with a coat of Bondo auto body filler. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512418534-2O06IS9XZDN5N4KWHKTR/witchking_old04.jpg Projects I sanded the surface mostly smooth, leaving the naturally-occurring voids. The voids nicely simulate corrosion or damage. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512418731-USBH6MBR2K1P7LKSYX1F/witchking_old05.jpg Projects I glued on the spikes with a dollop of hot glue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512419123-IE4YINQDO0JG1PZ860ZP/witchking_old06.jpg Projects I used epoxy putty to make the base of the spikes, texturing the putty with coarse sandpaper. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512419308-317UN9O6RBC3VQPEVRNK/witchking_old07.jpg Projects I painted a base coat of black over the entire helm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512419620-6IAC4AA6E7H7S26F1FWP/witchking_old08.jpg Projects I used an iron based paint, leaving black exposed in the recessed areas. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512419899-JS8G0K4KKLUZXUUPZRTB/witchking_old09.jpg Projects I went over the helm with a wash of black to accent the recessed areas more. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512420408-WG2FVBXX71ATVP5PRZVD/witchking_old10.jpg Projects A final drybrushed coat of silver pulls it all together. Edges are hit with a highlight of silver to simulate scuffed metal. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512420499-TCB47R6LEAPKT7TU80HG/witchking_old11.jpg Projects The final helmet modeled on my head casting. I made a black hood to be worn under it hide my face. Visibility is not too bad. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512420785-P4U5KP255Y8OT1F1YU6O/witchking_old12.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512420855-R67BBQPNORLH6T8K3IVC/witchking_old13.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512421284-TA7J80F4CPYVKYZYGX5V/witchking_old14.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530512421306-XELIFVBP346ITBSDJS78/witchking_old15.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829507930-NVN3RYNHTJP0ZIYRTP9M/parallel_old01.jpg Projects I was commissioned to make a replica of the dimensional jumper from the Doctor Who Series Four episode “Journey’s End”. This was an updated design of the device from “Doomsday”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829508037-5AASDO1B9YSR40T4F5DJ/parallel_old02.jpg Projects I started with a block of Basswood and shaped it on the lathe. Here it is with a coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829508444-LZP4HRA9PPUPYAIG73PL/parallel_old03.jpg Projects The basswood is soft enough that I could hand carve out a section for a block of maple. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829508675-2AYIB8PWQ42FGLAW5QTL/parallel_old04.jpg Projects I used tin snips to cut the metal “tongue” out of an old hard drive sled. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829508964-7OSP8W3P2Z0FQZ1FP3YY/parallel_old05.jpg Projects I chucked 1/2″ dowels into the drill press to make a “poor man’s lathe”. I shaped the pegs with files and sandpaper. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829509077-3Q4XLIVOW5DYAP7MIQG9/parallel_old06.jpg Projects I cut a small piece of styrene to form the bridge connecting the two rings. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829509500-PGHPIO3H9LQHUO3BXKAF/parallel_old07.jpg Projects I attached some scrap plastic to a lathe faceplate and very carefully scribed the center disc lines. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829509594-Z5Y8QT9AI62HSVAWMUJ9/parallel_old08.jpg Projects A test fit of the peg. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829509929-G9ILVSJORLKG5ASZVH3K/parallel_old09.jpg Projects All the parts finished and ready for painting! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829510280-4REMU7U56ZRCIJFVE8CU/parallel_old10.jpg Projects The final assembled prop. The center yellow is a florescent yellow that hopefully will look lit up under a camera flash. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829510411-SVP1285D3HVBNNICOJLP/parallel_old11.jpg Projects Side view showing its dimension. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829510744-A814NTWCZ8WX7C61PGZH/parallel_old12.jpg Projects It fits pretty comfortably in your hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829690676-MEXGEO08ZLGNJTSATZNS/Emperor01.jpg Projects I was commissioned to build the sword of Emperor LeLouch. A scabbard to fit it was also requested. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829691125-KOP6UAYE1RJQ6VZQNPJ3/Emperor02.jpg Projects Since the blade is so thin, it would be difficult to insert a steel rod like my other wooden swords. I decided to make it from a solid piece of 3/4″ maple, cutting the side profile on the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829691432-L59UYSXIB2A5W91BYZ55/Emperor03.jpg Projects I then tapered the thickness of the blade using the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829693128-FLJ4H65QCYJ82I0CBHR6/Emperor04.jpg Projects I used a hand plane to bevel the edges of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829694471-J88MHC9UNQF1ZQOZJ1MG/Emperor06.jpg Projects I cut a slot in the top of the blade big enough to insert a 1/2″ copper pipe which will serve as the handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829692950-D51OOGW39SB9VU4P5SSV/Emperor05.jpg Projects I cut 1/2″ MDF for the guard, running bolts through all the pieces to hold them together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829696867-RQ89U22OEN631ZP1S249/Emperor10.jpg Projects The guard was getting too thick, so I re-cut it in 1/4″ thick MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829696336-D7L194SZDPET0RXU7J31/Emperor09.jpg Projects I then cut the wings from 1/4″ poplar and filled the gap between the MDF with more poplar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829697414-7CTZ6ZYKVXYJ2GDJESAC/Emperor11.jpg Projects Once everything was bolted and glued together, I puttied up the seams. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829697740-PGO6HO5JUUNS9HIC7EQN/Emperor12.jpg Projects To further reduce thickness, I also re-cut the outer trim from 1/4″ poplar. These also cover the bolts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829698435-TMC7AM1HK27TR5DM5TMP/Emperor13.jpg Projects I routered out some shallow holes in the sides of the blade to hold the gems. I also cut some thin plastic to smooth out the bottom of the hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829698730-VA7XWM5197LX2UIT9ZAC/Emperor14.jpg Projects I made the blade gems using 1/4″ acrylic, shaping it with a Dremel sanding drum. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829699175-K5V4U8LYXBCPIPZL8BLI/Emperor15.jpg Projects After sanding, the gem was smoothed with a buffing wheel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829700179-NTH8UIQ4HTFHH8SL5175/Emperor17.jpg Projects I cut trim from styrene and glued them to the holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829699574-76EVVS5Q0B32EJBUE1Y7/Emperor16.jpg Projects The feathers on the wings were scribed using an Xacto knife. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829700783-DP4GWP6XEJ1DTHBCOIEZ/Emperor18.jpg Projects The handle trim was made by heating and wrapping thin styrene strips. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829701040-4SNIGWRZ5KHBFRV92J84/Emperor19.jpg Projects Once it was wrapped around, it was trimmed flush. The ends were heated again and the softened plastic was mashed together, welding the seam shut.. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829703988-W1NDGB3YNPGBQEFO7XM6/Emperor24.jpg Projects The plastic trim glued to both ends of the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829704613-RMA4BP80FPS6PB9FUYRF/Emperor25.jpg Projects The pommel was a wooden drawer knob, secured with a threaded rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829702024-KTXQXHF2DCDJ2YY148DM/Emperor21.jpg Projects The hilt gems were cut from 1/4″ red acrylic. The base was cut from thick styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829710283-MEIT3TUUOQN91IGATVSF/Emperor27.jpg Projects I glued mylar wrapping paper to the back of all the gems which reflects light through the plastic, really making them shine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829701794-UHHRIIUPU8GLNMND68Z5/Emperor20.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829702628-I74DCC4P9WK88D2DMQ1U/Emperor22.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829703847-P0N2VAKSRJIID0X3WS4H/Emperor23.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829707439-26KNRXHEA9TL24RAG68L/Emperor26.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829710399-W6V0Y9RXNPRECSN3NN5B/Emperor28.jpg Projects I painted the hilt in two gold tones. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829711693-Z1CYND9CPZK5OX7PGSC7/Emperor29.jpg Projects When I got a shipping estimate, I found that the sword was too long to ship cross country for a reasonable price. The only solution was to cut the blade in half so it fit in a smaller package. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829711806-J6MM3FPA27Z0K8ADT2HF/Emperor30.jpg Projects Fortunately there is a natural color split at the halfway point so the split wouldn’t be too noticeable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829712690-1P4FAN2RIM5GKJMW6VLA/Emperor31.jpg Projects I drilled each end and glued an aluminum dowel into one side. The dowel in combination with epoxy will make the blade as strong as the original wood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829712931-ZACYWV0WGJW6SJFY5FOR/Emperor32.jpg Projects Back together! The client will epoxy it when he gets it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829714044-BNFTLODFSCSJXAD8FGC8/Emperor33.jpg Projects The round beads were purchased and painted but I made the long beads from maple. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829714069-J0V8LQP3X41VL1RIDPC4/Emperor34.jpg Projects I glued some string into the end of the long bead and strung the round beads and grommet onto it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829715050-SEJX4UG6L1DQ49UFWZ5S/Emperor35.jpg Projects The final sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829715481-J7W6R2KKAJERZY1K9OZR/Emperor36.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829715897-TFGCN7WNPURZO3EV55NW/Emperor37.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829716219-5WUP2BOEPAJSLSPYNFUG/Emperor38.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829716702-27YW24M261T94FYGUG3S/Emperor39.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829719640-UQJL7OR03FZU0DOCAACZ/Emperor45.jpg Projects I also built a scabbard for the sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829716808-LG43THT87V958JCCRCM5/Emperor40.jpg Projects I added two rings to the scabbard so that it could be worn from a belt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829717662-V734JKKTCO0VKPDE7K2L/Emperor41.jpg Projects I heat formed styrene trim to the opening, keeping the trim away from the end to protect the sword from getting scratched. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829717816-YWGEBJHLKND1V5K28MM7/Emperor42.jpg Projects The tip was also formed for heated styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829718586-65O6FHWA2Q89GRU4FH6G/Emperor43.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829718882-8P3STSRS330AJSN9ZRYG/Emperor44.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829720472-66VB27I0IEDMHELR4ZEJ/Emperor47.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829721276-TZ86HQQY7413SFI9244L/Emperor48.jpg Projects The sword outside the scabbard. The sword itself is over 5 feet long. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829913294-KR0T7QC2QIBYBO1T2MK6/roto_old_25.jpg Projects I was commissioned to make a replica of the Roto’s sword and scabbard from the game Dragon Quest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829913389-A5R2699X94P5GAJILBPD/roto_old_26.jpg Projects For the blade, I glued together two sheets 1/4″ Poplar with a channel cut to contain a 5/16″ steel rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829913756-X2DD5H7HMY6FDR27EWVX/roto_old_27.jpg Projects After cutting the profile, I shaped the blade edges on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829913932-GEWHQZRKESAST7TWQ1IO/roto_old_28.jpg Projects The grip was shaped on a lathe from basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829914113-IVPWY7IEDTJLOWS202AQ/roto_old_29.jpg Projects I used a long bit to core out the center to house the steel rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829914679-NGPB007EH4YNB36H5GUY/roto_old_30.jpg Projects A test fit of handle on blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829914722-KHAWEFU6TR8JAOHOC63R/roto_old_31.jpg Projects The center rune strips were cut from thick styrene. I found Norse runes that closely matched the reference and carved them into the plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829915447-4S5Q2XQYFI197OCTKO2I/roto_old_32.jpg Projects For the pommel, I lathed a yoyo shape from basswood and then drilled out the base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829915546-OCAVCNQFJW0A5FCB2P9N/roto_old_33.jpg Projects The pommel now fits perfectly on the handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829915884-PYKTE4MIEFPQ2PXID0D2/roto_old_34.jpg Projects I glued three pieces of MDF to form the guard, leaving a channel for the blade. It was rounded on the router table. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829915969-18GO4GXQZ3NVTG5OYC5J/roto_old_35.jpg Projects I used a series of files to carve grooves into the curve of the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829916267-QOU8TMA3FKOPK80VLQGP/roto_old_36.jpg Projects I glued the guard on to the blade and puttied up the seams. I also inserted screws to give the guard extra strength. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829916403-8M967ER5L47GSUSG3XL1/roto_old_37.jpg Projects The “bird” shapes for the guard were cut from thick styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829916722-8X15DZ35UU28MHV47JLP/roto_old_38.jpg Projects I glued on the center rune strips. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829916871-EN10MGK4I6G1EOGB81SR/roto_old_39.jpg Projects To bridge the distance from the rune strip to the bird, I cut some MDF spacers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829917448-9N40MYUJGWROYX7F8JP0/roto_old_40.jpg Projects Once the styrene was glued down, I used a heat gun to form the “feathers” around the curve. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829917603-7JEXBGOXH61WB37YIEDB/roto_old_41.jpg Projects Once both sides were shaped, I puttied up the seam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829917936-NYEY93N8UHMMJW3ZOA8D/roto_old_42.jpg Projects A quick coat of primer to see progress. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829919883-F26JTUAFG8E3M48Z9TV7/roto_old_48.jpg Projects I made a scabbard box from 1/4″ MDf and reinforced it with MDF in the inside corners. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829919188-AZ6ZZLKQS9GFJXNFWKTI/roto_old_46.jpg Projects I found some nice thick leather to wrap around the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829918783-AVHERGTEE8J58REYFL62/roto_old_45.jpg Projects The scabbard is to be carried across the back so I got a D-ring as an attachment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829920168-LPTZGWI7439X8FSXMQVM/roto_old_49.jpg Projects I glued black felt into the inside of the scabbard to protect the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829921240-YIMWXQBHEKYI7TTKKH75/roto_old_53.jpg Projects I heat formed thick styrene plastic over the tip to form the end cap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829921325-P9GL43U6K9ECRLM3HAR8/roto_old_54.jpg Projects Once the imperfections were smoothed out, I cut the decorative slots with a band saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829921691-42AU3H0Y7BGT1615JNVD/roto_old_55.jpg Projects For the scabbard collar, I heat formed more plastic around the opening. The blue tape is protecting the felt interior from dust. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829921869-FX1HZ0YUKKJCPAXRX3WL/roto_old_56.jpg Projects I sealed the seam and cut the curved base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829922154-R731RR3VLAT2XJY52NVR/roto_old_57.jpg Projects I glued the cap and center band (also heat formed plastic like collar) and gave it all a pretty coat of primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829922240-N3UF4OCOMBRG5OSKPZAD/roto_old_58.jpg Projects I painted the blade and top coated it with Future to protect the finish. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829922732-SAZXHNJCL4UD5CQO08YX/roto_old_59.jpg Projects The scabbard and all the “hardware” was also painted. The red applied smoothly…any imperfections you see are from my dusty fingers. It wiped off before top coating. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829923058-8SNMU31YRB75MGR7OKSC/roto_old_60.jpg Projects I applied some extra felt on the top edge to protect the guard when it’s put in the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829923133-G9ZRPB8Z1DKBH2XPQUVK/roto_old_61.jpg Projects Once the collar was glued on, I cut the slot for the guard for a proper fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829923447-4MHI0S8Q2DOF4RA44A8P/roto_old_62.jpg Projects A test fit showing the sword inserted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829923597-AJ11NUXEP79N73AUEPQZ/roto_old_63.jpg Projects I cast some resin gems and glued them to both sides of the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829923891-4CJ4UR3AFWWVEUZ6QNB0/roto_old_64.jpg Projects I glued the leather to the scabbard and used upholstery tacks to simulate rivets. I trimmed the nail so that it only went 1/8″ into the scabbard surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829923975-JDE5GU7DWEVIKSSUQ2MV/roto_old_65.jpg Projects The back of the wrap covers the ugly rivets! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829924218-R24LU7Q3DR81X7SRE0QH/roto_old_66.jpg Projects The final sword! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829924402-JW22GYXTKAOQ8XRZVDJ5/roto_old_67.jpg Projects Sword in scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530829924621-Y3BE58GVPLE0262S6D5U/roto_old_68.jpg Projects The sword in the hands of the client, battling robots! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997454544-H9A143LM50DS381YKVBU/ragnell_old_01.jpg Projects I was commissioned to make Ike’s Sword Ragnell from the video game Super Smash Bros Brawl. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997455058-3R82ZOKSSLJI4ZO59KZ2/ragnell_old_02.jpg Projects I started with a 5/16″ steel rod for a core. I cut a channel through a 1/4″ thick plank of poplar to contain it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997455519-ZUMIOQEPVDDJW14IUNGC/ragnell_old_03.jpg Projects I glued 2 more 1/4″ poplar planks around the steel and cut the blade profile. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997455922-HE339XYN5IGIUKNHTMP2/ragnell_old_04.jpg Projects I shaped the edge on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997456556-US8HS6G2KC44YUAH9CDK/ragnell_old_05.jpg Projects Much paint and putty later I smoothed out all the bumps. The decorative piece at the hilt is carved out of 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997457174-FP9PTGCDCNKN7Q0P4NGW/ragnell_old_06.jpg Projects The cross guard was cut from 1/4″ poplar just like the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997457499-455CYEKZLU8U4DVVUC2T/ragnell_old_07.jpg Projects The cross guard was detailed with plastic sheets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997458569-0CMA9X1CKQDC7FSY2FQC/ragnell_old_08.jpg Projects The second layer was added to both sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997459595-M9Q8JLZ67KWXB70BTVTC/ragnell_old_09.jpg Projects I didn’t like the blockiness of the guard so I popped off the plastic and sanded contours to the guard. I heat formed the plastic detail to fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997460223-SARWX3909289G0RW3RMI/ragnell_old_10.jpg Projects The grip was lathed from a pine dowel. I cut it in two so that I could drill out a channel for the steel rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997460622-MFYI320S4EY6VD7LFXMM/ragnell_old_11.jpg Projects I made the blade “case” from MDF and sanded it to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997461035-KQ4BW85GCHZS01KS3I48/ragnell_old_12.jpg Projects Once it was in place, I notched the case to allow the guard to fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997462486-GCPILFSPEXRCYAYC890I/ragnell_old_13.jpg Projects I heat formed more plastic around the case and cut the trim out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997463410-UT6OYPJG00PJAQTWOVX3/ragnell_old_14.jpg Projects I used a blade to cut ribs in the trim. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997465747-6J0LQ8ZT2OSZP5VAPXY4/ragnell_old_15.jpg Projects The sword assembled and painted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997466610-VX99AWXL9PJ3IY45IK1P/ragnell_old_16.jpg Projects The hilt was painted with a metallic flake black. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997471319-JN9BA90CZNJHIS39ED89/ragnell_old_17.jpg Projects Acrylic gems were glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997474260-3VJHPFPFF13Z7KKWNXJ6/ragnell_old_18.jpg Projects The sword in action! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997476199-0U5DK9POP4TMAYMI7474/ragnell_old_20.jpg Projects I later received a commission to build another Ragnell sword and decided to make some changes from the previous build. In order to keep the grip as one piece, I glued and bolted together two pieces of basswood after precutting the channel for the steel rod down the center of each side before lathing the shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997477179-M6ZV7T0W2AV6SZSLT0PD/ragnell_old_21.jpg Projects I made a template of the curve on the bottom hand grip and drew lines for the fluting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997477534-D3J6CFE4IBWBG9QAK7DN/ragnell_old_22.jpg Projects I carved out the grip flutes with blade, chisel and files. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997478376-T2FEOR6LLN9936TLXSWE/ragnell_old_23.jpg Projects The blade cap was made with pieces of 1/4″ poplar glued together instead of MDF. I shaped it on the belt sander https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997478832-WYHRW4CNNF03QB0F18AU/ragnell_old_24.jpg Projects After all the shaping was done, I filled holes and seams with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997479075-KS67VMUA3TJEKC0VTS64/ragnell_old_25.jpg Projects To get a tight joint, I covered the blade with plastic wrap and filled the gap with Bondo, squishing out any excess. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997479663-UJN9Z5PBCGU1XMZT1GGC/ragnell_old_26.jpg Projects Instead of using plastic for the trim, I used epoxy putty, sculpting and sanding it to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997481061-DI498BJP73YW7VN6VND5/ragnell_old_27.jpg Projects I used silver and black metallic Rustoleum paint on the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997481781-7NNC53U6G918LEHH4C60/ragnell_old_28.jpg Projects The final sword https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997482147-BXHPO00WIG653WFXJ1Q9/ragnell_old_29.jpg Projects Grip detail. I drybrushed some silver on the crossguard to bring out detail and tie the whole sword together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530997482585-8LZEBZXIJ7PUH8G9K7O8/ragnell_old_30.jpg Projects This is how it was shipped. The client could glue it together upon receipt, although the fit was pretty snug. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998720857-95H0FE433H9D36IHGCEY/silo_old_01.jpg Projects How could I resist building a model of Homer’s pig crap silo in the scale of the World of Springfield figures. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998720838-DQB58GBC4DJI8P1LCIAV/silo_old_02.jpg Projects I found a tube that was exactly the right diameter to be in scale with the Simpsons action figures. After drawing the plate pattern, I started glueing on thin plastic to simulate the sheet metal. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998721591-H4OXLPREFPRPSOLRCFNX/silo_old_03.jpg Projects After all the plates were glued on, I used puffy paint to add rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998722334-RG2J6U0ECM98KR2PYH9L/silo_old_04.jpg Projects I stacked MDF and sanded it to shaped on a “poor man’s lathe” to make the dome. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998722712-0Y412Y3BXW1V4C7E0O8D/silo_old_05.jpg Projects After the dome was formed, I used it to (badly) vacuum form plastic over it. The plastic was cut up to make the dome plates. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998722950-V1AEDR6HBEKU39GUEO5B/silo_old_06.jpg Projects I hand painted Homer’s “Pig Crap” message to the front… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998723436-TSMCK1XSIQ71153E3PKR/silo_old_07.jpg Projects …and his “Return” message on the back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530998723649-U0R8ZXAMEBZHA2ILBX44/silo_old_08.jpg Projects The final model with Homer and Marge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999317738-VG2DJQ7ZTG4ZBTN1UPCC/Mk_Hikaru00.jpg Projects I was commissioned to make a replica of the swords from the series “Magic Knight Rayearth”. Hikaru’s was the last completed of the trio. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999317859-VYSIXG0UIIBE9Z3WDFRL/Mk_Hikaru01.jpg Projects For the blade, I used 1/4″ Poplar with a channel cut to contain a 5/16″ steel rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999319236-0L8CUENFFGC45LFR0I2Y/Mk_Hikaru02.jpg Projects Once the basic dimensions were cut, I shaped the blade edges on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999319136-3SMAP5OPWWPGL2EBQO8F/Mk_Hikaru03.jpg Projects The blade was shaped to leave a 1/8″ flat edge to make it “convention safe”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999320468-9QKIQPS7L2O5UTQ9N7C8/Mk_Hikaru04.jpg Projects Much putty, primer and sanding later, I have a smooth blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999320373-WKT1PJAA2XJ1NVC3NWJF/Mk_Hikaru05.jpg Projects The handle was made from Bass Wood and turned on a lathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999321494-JXRP5KZ8Z6EZ1KHP9SEC/Mk_Hikaru06.jpg Projects I clamped a hand drill and cored out the handle with a long drill bit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999321596-4OL149JKO7LABKV3XXKP/Mk_Hikaru07.jpg Projects I then cut the scallops at the base of the handle… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999324221-PQTFC3ZAISNAJTURXGM1/Mk_Hikaru08.jpg Projects and used half-round styrene to make the trim. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999323836-BC4NWL5WMK5LSSA58JRF/Mk_Hikaru09.jpg Projects I formed the detail at the top of the blade with thick styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999326080-WJG4WLV40Y8ERGBZX709/Mk_Hikaru12.jpg Projects The flat gem detail at the blade tip was made with styrene and I filled the bevel gap filled with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999324822-4IF6FPJ4H5F5UGBSLFLE/Mk_Hikaru10.jpg Projects The hilt center layer was made by gluing 1/4″ poplar pieces. The second layer was made with 1/8″ MDF. The white plastic coating as sanded off. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999331325-3NAP4MEU0JYL9Q788BL0/Mk_Hikaru14.jpg Projects The hilt center layer was made by gluing 1/4″ poplar pieces. The second layer was made with 1/8″ MDF. The white plastic coating was sanded off. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999331669-T10HDAFND7XXQD3S7WA6/Mk_Hikaru15.jpg Projects I used a Dremel to round off the organic details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999332343-8QP0X3W490K84D1VIDEA/Mk_Hikaru16.jpg Projects A quick test fit of blade, hilt and handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999333782-22EVLZF5J54HQJOHUA6Y/Mk_Hikaru19.jpg Projects I started adding layers of 1/8″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999325687-0IUF1O5KXEIFBYZ3FQNC/Mk_Hikaru11.jpg Projects The center was built up with 1/4″ poplar sheets and trimmed with half-round styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999334580-DXD6VQOPF8616XW6OO6J/Mk_Hikaru21.jpg Projects 1/2″ MDF was used to make the base of the hilt center. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999335121-CO05QKA5SEYLNG7RQ4Z1/Mk_Hikaru22.jpg Projects MDF was shaped to make the center plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999337082-2JEHD0WY3IRFAF7JB3HX/Mk_Hikaru26.jpg Projects The final painted guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999339057-ZDI3L1C8FYQS153AWZJ0/Mk_Hikaru31.jpg Projects The pommel was a cast resin 2″ sphere. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999337194-DOLVXDB9KQK6MBOLXXGS/Mk_Hikaru27.jpg Projects Cast resin gems were added to all parts of the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999338314-70L57L775OAXRTT6GL0Z/Mk_Hikaru28.jpg Projects The final sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999338216-JKR93KU6OJ5M88WMP6HB/Mk_Hikaru29.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999340272-3D7BUGB4S9IJJD9EO09U/Mk_Hikaru32.jpg Projects The handle comes off for easier shipping. It will later be glued in place https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1530999341159-I48VA3M1DJXG7G42LWWR/Mk_Hikaru34.jpg Projects The sword finally in Hikaru’s hands! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000202522-BXX17FNW90M4MXOOH3TT/fuu.jpg Projects I was commissioned to make a replica of the swords from the series Magic Knight Rayearth. Fuu’s was the first completed of the trio. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000200533-QA1V00B2W9G27EKZKATN/Mk_Fuu01.jpg Projects The poplar wood that I use for swords only comes in 4 ft lengths. To make up the extra length, I offset laminated the wood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000202431-YSH3LYQ0IM530KQGF2XO/Mk_Fuu02.jpg Projects The wood glued together and cut to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000203532-JKP0AC7K5LX9D9AS4PZC/Mk_Fuu03.jpg Projects The handle was shaped on the lathe from Bass wood. I used a long drill bit to core out the center to allow the 5/16″ steel rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000203949-5UJ52CFAY6I5CZ0OPP3C/Mk_Fuu04.jpg Projects The collar of the handle has an irregular shape so I carved it out of the lathed shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000204856-TPFMPQHRCW1U9305SGQO/Mk_Fuu05.jpg Projects The completed collar minus the recess on each side for a gem. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000204956-GLZ965ZRQOTESZXB86NM/Mk_Fuu06.jpg Projects The pommel was formed by laminating 1/4″ sheets of maple. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000205775-1ZOJ9BICEGAZ0FEO196L/Mk_Fuu07.jpg Projects I attached it to a hand drill and smoothed out the base with files and sandpaper. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000206244-83BTT15QEMERXL6UM2IW/Mk_Fuu08.jpg Projects The final pommel test fitted to the handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000206867-8236REE2RE3PZ3YAOEBA/Mk_Fuu09.jpg Projects The final painted and assembled hilt with cast resin gems. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000208320-H366E2IS0FX5HWCLV2JR/Mk_Fuu12.jpg Projects The guard was made by glueing three sheets of 1/2″ MDF together, leaving a hole in the center for the blade. The guard rounded by router. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000208955-ROO5ANW1ZW139J6V46P0/Mk_Fuu13.jpg Projects After the surface was primed, I cut the bird details from .09 styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000209311-9941VDV369LDHM2CLQ41/Mk_Fuu14.jpg Projects I used a heat gun to soften the plastic and press it around the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000209745-I4VYDO84CIX12GZIQWQZ/Mk_Fuu15.jpg Projects I matched up the edges and puttied the seams. While the putty dried, I added the second layer of detail with .06 styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000212859-AYX6XKLCHFU0ZXOFP56E/Mk_Fuu18.jpg Projects The completed guard attached to the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000217006-VA2GREWD7447W0HKWNYP/Mk_Fuu23.jpg Projects The sword disassembles for transportation although it will have to be glued before using. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000215402-1USYAQJX8RQF4VP637KJ/Mk_Fuu21.jpg Projects The whole sword. It measures 7 ft in total length! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000215915-4Q6O76XLZZ4KWVY7RTYH/Mk_Fuu22.jpg Projects Detail of the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000217178-JBGHXM6UY7KHUBTA87JW/Mk_Fuu24.jpg Projects The sword with its new owner! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000854425-KSF19XH8FRVPUB6JXF96/Mk_Umi00.jpg Projects I was commissioned to make a replica of the swords from the series “Magic Knight Rayearth”. Umi’s was the second completed of the trio. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000856488-6O38XG7ANMH8FODH48YH/Mk_Umi03.jpg Projects Since this blade is so thin, I wouldn’t be able to run a steel rod in the core. For maximum strength, I decided to use maple. I constructed a jig to tape the blade at a consistent angle. Once the basic dimensions were cut, I shaped the blade edges on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000857427-ENO39DSPV26F0PU1ON5M/Mk_Umi04.jpg Projects The handle was shaped on the lathe from Bass wood. I drilled out the center to accept a 5/16″ steel rod for connecting to the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000857646-EADXU3W9U52OX8M1JBKR/Mk_Umi05.jpg Projects I used styrene sheets backed with Bondo to shape the upper blade area. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000859007-7LVES6OB491Q2B13GTGQ/Mk_Umi08.jpg Projects I made a quick cast of the guard area to sculpt the dragons out of clay. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000858204-8I22K6ZEG9UBSQJMIFE1/Mk_Umi06.jpg Projects I used epoxy putty to add scales to the dragon bodies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000859453-6GIB50T3PMNSMNPSADUY/Mk_Umi09.jpg Projects A test fit of the cast resin dragon hilt https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000860864-XO1PQXVKLQWKGR1HAH24/Mk_Umi11.jpg Projects I made a maple plug to attach the dragon guard to the steel rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000861702-5KYMROHUTV23JWRARSV8/Mk_Umi14.jpg Projects The painted guard with clear cast resin gem. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000862627-A78I0XXU38AA6KWDTBV4/Mk_Umi16.jpg Projects The final sword with cast resin gems. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000863227-MIPZ9SNYIO2UD0WSPA6V/Mk_Umi17.jpg Projects Guard area details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000863905-I4MHEI0O2PY1LST79YVV/Mk_Umi18.jpg Projects The sword disassembles for transportation although it will have to be glued before using. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531000864132-JMBKBJA94TGBJHDWFGFY/Mk_Umi19.jpg Projects The completed sword in Umi’s hands. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531375231435-BCQQCC62Y7X9BL6VQGMZ/walle_old_01.jpg Projects I finally got this Interactive Wall-E …it’s been sold out since Christmas. It’s great but needed a more accurate paint job. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531375231505-XKOJYFMM89SNL19OKDJP/walle_old_02.jpg Projects I applied browns and blacks to build up a layer of filth and applied rust to match stills from the movie. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531375231992-BPI7SJBKQSNG1L4X8E2O/walle_old_03.jpg Projects I applied washes of brown to define detail in the rubber tread and rust and silver to bring out details on the wheels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531375232082-6SWLX9D3N47AA9R1ZN7N/walle_old_04.jpg Projects I used black to apply dirt in the eye socked and silver to simulate chipped paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531375232538-UKL76LKLWCGSZBJ56E85/walle_old_05.jpg Projects I opted not to do a full overhaul where I would fill screw holes and make him more accurate. Eventually, I’d like to build a life-size replica. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531524292083-KZOGD7O1J3F3FX96LPBN/forks_old00.jpg Projects I was commissioned to make a replicas of Seth Nightroad’s blade forks from the series Trinity Blood. Since they are quite large, I decided to make them in parts that could be assembled later. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376316113-18AGN1J61P6NYZA52RYE/forks01.jpg Projects I made the center ring from 3/4″ MDF with a PVC handle. I drilled through the center to allow a 1/4″ threaded rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376316231-NFEPYLATZM0BF1WTTP6H/forks02.jpg Projects Nuts were glued into the ring and then secured with threaded rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376318012-HUMLADQIEOT4ROJ58T4F/forks03.jpg Projects I made the base from basswood shaped on the lathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376318018-EHX3CAJ1I6WIVZXR5LGF/forks04.jpg Projects The rings that make the ball cage were cut from a 3″ PVC pipe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376319195-Y82WO8Q2SDQW86D8XD66/forks05.jpg Projects I notched the rings so that they fit together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376319209-0MZPS05T35H3LIGNYJ89/forks06.jpg Projects The center ball is a wooden post cap that I drilled to allow a 1/4″ threaded rod. I covered the threads with aluminum tubing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376320666-AWHTCN70D66D29B35PCL/forks07.jpg Projects I cut slots for the rings in the base cone. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376320622-5TSJ6RLAQ1GBK8W4R6UT/forks08.jpg Projects The third ring in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376321721-U0DIGF3RAYWVASX1760I/forks09.jpg Projects The base parts glued together. I added a steel screw in the end to protect the wood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376329118-PJ8HB2X981PDR3G273GZ/forks21.jpg Projects There is a ring of spikes around the top of the base unit. I needed a 5″ plastic ring so I found a large PVC connector that I could cut rings from. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376329276-ER9OIOPJG6FVQRQIZ7WB/forks22.jpg Projects I used brass tubes drilled into the wood to support the plastic ring. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376330641-KTBJKOSEAKUQCGG8213Y/forks23.jpg Projects The ring was held in place by wood dowels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376322714-I2C85A8R03POXQ3REZZV/forks11.jpg Projects The blades were made from 1/4″ oak with oak dowels glued to the side for support. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376323143-QLXH9S742QE4XLP9IVK1/forks12.jpg Projects The blade base was shaped from blocks of pine and glued to each side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376323748-LXMIMJWF3HYMH0M357TR/forks13.jpg Projects The blade support arms were made from 1/2″ threaded rod, bent to angle and then glued into the ring handle. Brass tubing covers threads where I could use them, Bondo will cover the rest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376324193-MN5LYV1UY75OPEP46AIM/forks14.jpg Projects Threaded nuts were inserted into the blade bases. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376324990-4YSAV7MID9C06C81PJWH/forks16.jpg Projects I lathed some wood cones that form the end of the support arm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376326309-90ZB6D1BXNF6X519W9VE/forks17.jpg Projects A base for the ring handle was made from pine with threaded inserts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376327833-SVBW2W7PLUTMDZW3IIBX/forks19.jpg Projects The completed upper assembly. The spikes on top were made from pine blocks. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376326495-JS7OMEZ40SNGESXVF8B8/forks18.jpg Projects The staff section was made from PVC with a wooden dowel inserted to support a threaded rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376331639-LHR5YLJ77WWBSM6MG324/forks25.jpg Projects To ensure the safety of those within poking distance, I decided to make the spikes from urethane rubber. After shaping a wooden master, I used clay for a simple push mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376332205-REEITJQZ1VT5CCBD3UHS/forks26.jpg Projects All the rubber spikes for both weapons! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376332583-9WP8N7A7JQY1KH91PE9R/forks27.jpg Projects The rubber spikes glued to the ring handle. A light dusting of the same gold will make it blend in but will remain flexible and non-deadly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376333062-OSUXXEERJ5KGO6MIP52J/forks28.jpg Projects The cage ball was painted with an iridescent red paint and the spikes were glued on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376333899-OALWG85WDW4O3CYF4O45/forks29.jpg Projects The completed forks beside a 48″ ruler. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376334103-LBXORSUN2SLTQWXIAS4D/forks30.jpg Projects Detail of the blades and handle. Rubber washers help keep the sections from loosening. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376335045-J9QUB1G76M5ABVMQLYZZ/forks31.jpg Projects All the parts disassembled for easy transportation. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376647760-H7DC4TMQXISRETUMRJGA/Caster1_00.jpg Projects I was commissioned to make a replica of the Caster gun from the series Outlaw Star. As an additional challenge, the client wanted it to be able to load the shells into the breach. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376647872-DP8ZXG1KAP59XF7LXKD5/Caster1_01.jpg Projects I started working from the inside-out by making a master for the shell from bass wood. The shell is about 3″ long. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376649471-IYW40M63DAB01CY0U6S6/Caster1_02.jpg Projects I masked off the design and then sprayed several coats of primer to build up some thickness. When the tape was removed, I had inset markings! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376650926-3J7BGHFS37H482N2IT53/Caster1_05.jpg Projects I made a mold of the master and cast five copies in resin. There was some cleanup to do but they came out pretty clean. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376656513-LJEE2XUU8H09LNRKVL14/Caster1_11.jpg Projects I used a PVC pipe for the receiver and drilled a hole for the pivot arm section. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376656524-Q4PECTNN7JZAYC4OI568/Caster1_12.jpg Projects Luckily, a PVC connector was exactly the right size for the pivot…no trimming needed! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376657340-ZI1JVPWDRE0PV040WKBB/Caster1_13.jpg Projects I cut off the end cap and plugged it with MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376653410-6EE56S7PFTP0L64SKXDZ/Caster1_08.jpg Projects I cut the grip halves from 3/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376655336-FGAB0WFBIP6V16LULG5U/Caster1_09.jpg Projects I planned to use a wood screw combined with epoxy to attach the grip to the receiver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376655549-4ZWGACI6OJL66C41YCFU/Caster1_10.jpg Projects I carved the recessed areas to the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376657568-C9WV7H5JPR7PHGSB0JJ3/Caster1_14.jpg Projects The slide was made from a section of PVC. I lathed an interior to the cap from MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376658517-1W4P50MPDIVXFIGF3WVL/Caster1_15.jpg Projects I cut a slot in the pivot PVC to allow the slide to move through. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376658636-RTAXYPSOIZ3RJQ0UK2FY/Caster1_16.jpg Projects The closed breach. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376659726-UD4LVUU59VIWZ7K4LNYY/Caster1_18.jpg Projects The trigger assembly was made from an acrylic rod with a sliding aluminum tube inserted. The trigger was made from laminated styrene sheets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376660695-EPTPH2FR712DJFQJ66RI/Caster1_20.jpg Projects I screwed and epoxied the grip to the receiver and capped the pivot with 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376661250-K0CYYB9WT2DVZLH7AYOT/Caster1_21.jpg Projects The trigger guard was made from 1/8″ styrene with an aluminum rod connecting them. There is a compression spring glued behind the trigger so that it moves forward. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376663445-LK1I9QLCA5I82QHSUSRJ/Caster1_24.jpg Projects I turned the barrel out of Bass wood on the lathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376661790-68QEZLCD17DYF7XSXJO8/Caster1_22.jpg Projects The pivot arms are made from stacked styrene sheets on a steel base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376663328-C2OUK058Y7RWL4O6NYLH/Caster1_25.jpg Projects The brackets that hold the other end of the trigger piston are made from 1/8″ styrene. I made a small chisel to carve out the slots in the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376663974-2RVPP15YPXJLKME72SNF/Caster1_26.jpg Projects I glued on half-round styrene piping to the gun. The tight curves were heated first. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376664828-E3XN6T8CUCKBV4A62K7Q/Caster1_28.jpg Projects The piping completed and primered. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376665152-PJX3VAHCQAXD7OC4D3O0/Caster1_29.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376665750-UTZL7JATD5Y87Q7YWA33/Caster1_30.jpg Projects The sights were made from 1/8″ acrylic rods glued to styrene blocks. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376665967-4J3ANRUPUCYZNYHA5H0N/Caster1_31.jpg Projects I heat formed styrene rods for the tubes on either side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376667198-ZNG6XVB07KVNZBP3997L/Caster1_32.jpg Projects The only gold color I could find that matched my screen caps was a Krylon Farm Equipment paint. It has a great industrial texture that makes it look like cast iron. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376667744-RDS6QEPAS1H1APFTPEWJ/Caster1_33.jpg Projects I back painted green acrylic and inserted it into the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376668208-09R7XZF9BBT5F9LW05B8/Caster1_34.jpg Projects The muzzle ring is glued on over the acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376669203-U9ANNZ8QM3L368D3V9UF/Caster1_36.jpg Projects The vents holes were cut from a thin sheet of styrene. It was glued over reflector tape…. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376669637-I0WCQERJJ6H1WDJ7TJCR/Caster1_37.jpg Projects …so that it would glow under a camera flash! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376670023-E9AO3D1FQ5GVQRULGPJG/Caster1_38.jpg Projects Here is the final assembled gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376670702-Q3SQB576NAVELSOMZHZC/Caster1_39.jpg Projects The individual shells painted to show accurate specs. FYI, there are 20 different shells on the show. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376671047-F67Z76P3SKCMB1Y1YRXE/Caster1_40.jpg Projects Detail of the receiver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376671449-7PTLFOJ22HTS4J8QQBML/Caster1_41.jpg Projects Detail of the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376673377-D923X573JYBOB160EANH/Caster1_45.jpg Projects The arm swivels down and the breach opens. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376673911-LCFB54YY4XO2FA4YRGB7/Caster1_46.jpg Projects A shell inserted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376674813-TLI0P1Z2UEF594LBTYK4/Caster1_47.jpg Projects The shell seated. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376675860-J608QBN2DLPZWS3N0F9T/Caster2_00.jpg Projects After I created my original Outlaw Star Caster Gun, I was besieged with requests for another one. I was commissioned to create another replica in August of 2009 and with the help of my sharp-eyed client, refined the design to be far more accurate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376676709-SFD9EGLJ0BW4UW4CB15Q/Caster2_02.jpg Projects I started to build the Caster barrel by bolting two pieces of bass wood together for lathing. Since the barrel will be molded, I needed to be able to separate it in two halves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376676329-C7F400DLDZ68TK9N4PVO/Caster2_01.jpg Projects The barrel and end cap lathed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376678717-XFBTECIFO7ECF8Z6WVYG/Caster2_06.jpg Projects I made a master for the trigger out of a scrap of green acrylic. The grip halves were cut from 3/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376679077-NKV1W1I39Y0KBEYBIRFN/Caster2_07.jpg Projects I temporarily glued the grip halves together for shaping. I started by rounding the edges with a router. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376679765-BY9EW8EV2AP97RU6PG97/Caster2_08.jpg Projects After some shaping with the Dremel, the basic shape of the grip is done. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376680140-3K3ZVNM2OHERNSQ406PI/Caster2_09.jpg Projects I cut a slot in each half for the trigger to slide in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376684696-MW5YHXLKKD9X4SQC8ESR/Caster2_16.jpg Projects I built up the pistol butt with Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376685833-RT6EYEXHW4XC2JAPSGZU/Caster2_17.jpg Projects The grip piping was made by bending half-round styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376685924-7UW7PXWRI2ED5MU36VMK/Caster2_18.jpg Projects The grip finished. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376677026-JLAPQPK2SJ94ZOILGXCL/Caster2_03.jpg Projects I lathed the breach arm junction out of basswood. The missing chunk at the left broke off during the process and would have brained me if I hadn’t been wearing a face shield! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376677610-AU2REE9OMKJMDPYXTLJO/Caster2_04.jpg Projects I drilled out the center of the junction block. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376677996-VHBV4NNX0GRN77TGRX10/Caster2_05.jpg Projects The junction block in place over the Caster body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376681828-ZLS7C6Y8XT4LQASPC35N/Caster2_12.jpg Projects The breach lever arm base was cut from thick styrene plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376683058-4XSD59QJQPW6G2D835KK/Caster2_13.jpg Projects The arm detail was made by cutting layers of styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376687233-61ZF67Q72XUEPR4U70CC/Caster2_19.jpg Projects I added the piping to the barrel with half-round styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376690075-S25AMU55YUHWGBYT2536/Caster2_24.jpg Projects I used styrene to build up the breach details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376689027-55OM1B3VYT17S66D0A4F/Caster2_22.jpg Projects The inner seal for the breach cap was made with a slice of PVC pipe. I also cut away a section for the rear sight to mount to. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376691105-LMTW6WGA5ZSN6FMD5FS3/Caster2_26.jpg Projects The piston master was made with brass and aluminum tubing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376691276-Z65L15HIBUP46JLMLW6L/Caster2_27.jpg Projects The brackets that hold the piston to the bottom of the barrel were made with thick styrene. To cut the slot in the barrel for the brackets, I sharpened a steel rod into a makeshift chisel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376693236-VPR20QXFDLRQZPYE04DS/Caster2_30.jpg Projects I had to cut away part of the grip to make room for the trigger guards. It looks sloppy here but I was able to clean up the seam with putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376680812-OVPLB10ZF2BXGIFKB6JC/Caster2_10.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376681310-HLEOVAE16EA7II0QOMFJ/Caster2_11.jpg Projects The rear sight was made by drilling a hole in acrylic cabochons (domes) and gluing them to the ends of a brass rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376690301-QZCXEFO6BAWC5I4W985A/Caster2_25.jpg Projects The piston master was made with brass and aluminum tubing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376699415-UCRNJNA2U5DDZ74VK1QR/Caster2_42.jpg Projects The rear sight was made by drilling a hole in acrylic cabochons (domes) and gluing them to the ends of a wooden dowel. The base is MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376700523-0B2BC9XH19BB0HYPM7MQ/Caster2_44.jpg Projects Test fitting the breach arms so I could place the small guide dome. Placed correctly. it limits the breach arm’s range of rotation. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376701360-K2GULD4B2JYXCJOCJL2P/Caster2_45.jpg Projects Test fitting the breach arms so I could place the small guide dome. Placed correctly it limits the breach arm’s range of rotation. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376701521-4PFHXPH5VTVJ0KF9Y66D/Caster2_46.jpg Projects The lowered position. Note the guide dome is at the bottom of the slot. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376702049-XP5EJ8WJKTMPYOCVIMTK/Caster2_47.jpg Projects All the parts ready for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376703871-XYJDYEOKALPQF8UH9IVE/Caster2_48.jpg Projects My friend Volpin volunteered to make the molds for this project. Thanks, dude! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376704027-LLBLSPC0Q9RR2UBRGIWU/Caster2_49.jpg Projects First set of resin copies from the molds. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376706338-QXU11EJSJTN85KXEJ345/Caster2_50.jpg Projects I drilled out the holes in the arms. I will be using the sleeves from pop rivets to connect parts and act as hinge pins. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376706559-XMFQ2TBAOBAMEBEJZAWR/Caster2_51.jpg Projects Holes drilled and test fitting of rivets for the trigger guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376707760-FQ0QU7S7ATU6UGYY1FE3/Caster2_52.jpg Projects Hole drilled and test fit of the piston. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376708172-QDZCIE0RT6Y27TI9859C/Caster2_53.jpg Projects I didn’t plan the trigger very well so I had to do some adjustments to get it to slide properly. I inserted a steel rod into the back of the trigger that would slide into a tube, keeping the trigger movement smooth and linear. A small spring from an pen snaps it forward. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376708726-WP9L6MTES8MTNWA2FHHE/Caster2_54.jpg Projects I had to make a breach insert that would keep the shell from falling down the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376711785-ADPOXLNFE0X4CNVOUJV1/Caster2_57.jpg Projects I wanted to use aluminum tubing for the trigger guard connector and the breach arm bar. Unfortunately the rivets are much smaller than the inner diameter of the tubes. I made and cast resin adapters to make them fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376712013-OGNZEPGQNR3HXFYSVLZ4/Caster2_58.jpg Projects The trigger guard spacer in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376714033-HCQX9W20LVKGZZGNVH3C/Caster2_59.jpg Projects I used a 3/4″ PVC pipe for the barrel of the caster. I painted the inside black and attached it to the lower barrel with epoxy putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376714045-VYPIXB03KFZVXG7ABP10/Caster2_60.jpg Projects I had to drill out the breach cap to allow room for the shell when it’s seated in the breach. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376716114-M9X70SPJI5JSBAEMXSY6/Caster2_61.jpg Projects I cut aluminum bars that slid in resin sleeves to allow the breach to open. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376716121-GL6NGLPZDV16S1UBAUT8/Caster2_62.jpg Projects After several failed attempts to cut the hole with drill and file, I gave up and had rail guides cut with a high pressure water jet. Perfect! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376718075-OOJ86NYM81XA0HXW7VOY/Caster2_64.jpg Projects I used a screw to stop the rail from moving out too far. The rails needed a slot cut out of the center. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376718215-EKOP2CRKSS6XFU2MXP2D/Caster2_65.jpg Projects Now with the breach resolved, I could seal up the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376719321-6TUO8131NS6ZQG9X1VLM/Caster2_66.jpg Projects During a test fit, I discovered that I didn’t make the breach arms long enough for the bar to clear the edge of the cap. I took resin arms and cut off the ends. The gap was filled with Bondo, sanded smooth and then I made a new mold for the arms. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376720554-X37NLCNL4FIQH7W7U3UC/Caster2_69.jpg Projects The final pained gun. After testing over a dozen different paints, I found the perfect Caster Gun brown! It has golden tints (that I mistook for gold on my original Caster) but is light enough to contrast nicely with the red piping. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376721324-F75OQOR9YAI8RXJMD1WM/Caster2_70.jpg Projects Muzzle detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376723170-FGVY11FZA7GKKP7YUB1W/Caster2_71.jpg Projects Grip detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376723270-ND2OWHAHU85O64WFNTLV/Caster2_72.jpg Projects Open breach. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376725418-B2JEFAD4WETO34YERHY9/Caster2_73.jpg Projects Shell loaded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531376725647-3ZAB2U5QESECHJA5MVF1/Caster2_74.jpg Projects The final painted shells. Pictured (L-R) #5, #12, #4, #9, #13 https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150814483-H7R3G0I666HZEGAMOCXH/ritona_old00.jpg Projects I was commissioned to make Yoko Ritona's sniper rifle from the anime "Tengen Toppa Gurren-Lagann". https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150814512-0UKP7G61MBBTYUOX5YAM/ritona_old01.jpg Projects The pistol grip was cut from 1/2" MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150814954-GL979JPHWX9F0SJVP2VM/ritona_old02.jpg Projects I cut the trigger from styrene and made the pivot from a nail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150815055-OAB2GCJWUHLB9IKR4Z6Y/ritona_old03.jpg Projects I used small torsion springs to force the trigger to the forward position. Styrene was used to line the interior of the trigger cavity and poplar was used to make the trigger guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150815458-UFZ93JSNSW3S4687DZMU/ritona_old04.jpg Projects The muzzle block started as a 2" x 2" block of poplar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150815558-J5QZ8G1OU9BI2GZTX3T2/ritona_old05.jpg Projects I cut the angles on the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150816005-3IL8BOQVGJ5HGLYNN7AC/ritona_old06.jpg Projects I threw it on the lathe and shaped the end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150816237-NW2POEP8CQ53LJJS41NG/ritona_old07.jpg Projects I drilled 3/8" holes on each side for vents and drilled a 1/2" hole in the end of the muzzle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150816583-H1CGPOCB7ICCJNQZ2E42/ritona_old08.jpg Projects The magazine sides were made from 1/4" MDF. I cut decorative slots in the sides with the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150816869-N7PE9CO3A9JLDUTXCFVA/ritona_old09.jpg Projects The complete magazine boxes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150817047-LHWDJVSRUAPP9SBZYZ61/ritona_old10.jpg Projects MDF forms the box that holds the magazine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150817574-7EZVLJDDOD0KCXQFQ0ML/ritona_old11.jpg Projects I formed the magazine release by hammering aluminum sheet around a steel bar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150817727-3GI05N29H439H2DC4INR/ritona_old12.jpg Projects The shaped release lever, pivot pin and slots cut into the grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150818082-88F3ORN11Q8TJQVXEX0M/ritona_old13.jpg Projects The release in place. A small compression spring keeps in pressed forward. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150818461-87A0MYLB15XMBT37MRLZ/ritona_old14.jpg Projects The body of the rifle is a 35" long piece of 1-1/2" PVC pipe. The rings at the rear sling loop and bipod were formed by cutting sections from a PVC connector. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150819314-A13AAN75O8MKD2XYZ3M7/ritona_old15.jpg Projects The butt was made from a sheet of 1/4" MDF sandwiched by 3/4" MDF. I sanded the interior curve to meet the PVC body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150819576-AQSAFX93YIP24ODD99UM/ritona_old16.jpg Projects I drilled through the top of the PVC so I could access interior screws to hold the butt in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150819901-L1JU1354VT7K687L4ELU/ritona_old17.jpg Projects For the bolt slot, I drilled two holes and then cut between them, removing a section of the PVC. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150820487-0KQDZCCHXCPK8B34JBVM/ritona_old18.jpg Projects I inserted a 1-1/4" PVC pipe into the 1-1/2" PVC body to form the bolt. For the handle, I used a socket screw and a bit of brass tubing to cover the exposed threads. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150820537-JO3N1SOKPI12R4THPFJD/ritona_old19.jpg Projects The assembled body so far. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150821150-2J38FYFM83G1Y7EYS83Y/ritona_old20.jpg Projects To cover seams and make the butt more solid, I wrapped it with .04 styrene plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150821204-GOTROU1C0GZ2DXFTD7N6/ritona_old21.jpg Projects I glued on some styrene strips along the edge. The bolt insert was capped off by a styrene plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150821565-6CKG7706LF51ETQSMCFC/ritona_old22.jpg Projects The sight rail was glued and screwed on the top of the body tube, conveniently hiding the holes for attaching the grip assembly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150821757-7LFEBP4HD33BQOBIOKE3/ritona_old23.jpg Projects I found an inexpensive folding bipod at the Sports Authority but had to cut of a bit so it would fold up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150822035-DAJYCY9NSP10UTVVPFZC/ritona_old24.jpg Projects I used the supplied screws but attached the bipod from inside the barrel, through two access holes I drilled above them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150822404-VFAHPK8SZZ4D1EOYH8RR/ritona_old25.jpg Projects For the feet, I cut a square of steel and epoxied them to the legs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150822525-ZEYFHF941D79NUFAVY7M/ritona_old26.jpg Projects I cut panels from sheet aluminum and attached them with pop rivets to the legs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150822804-SR0VK485YNQ16GVGZ8TU/ritona_old27.jpg Projects The completed bipod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150822904-H8W74P3CBCGXC4YDWGP0/ritona_old28.jpg Projects The bipod folded up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150823192-55DJM6WZRUA0Q5EFKTHR/ritona_old29.jpg Projects For the barrel I used a 1" oak dowel. The fit wasn't tight so I used a section of PVC to act as a spacer. The slot at the bottom allows it to pass by the bipod screws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150823294-DO20KN9VLJ00HWZJPDN9/ritona_old30.jpg Projects Once inserted, it's held in place by two screws that use the bipod access holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150823584-3T724HKBECFTEUQFTU72/ritona_old31.jpg Projects I bought a set of sling mounts that screw into the PVC rings on the body and the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150823680-X2RQ4A878B5351C8GELE/ritona_old32.jpg Projects The scope was made from PVC (front and rear sections), wooden dowel, lathed wooden cones and MDF end caps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150823967-WFLIJLY78U84SB2X08S0/ritona_old33.jpg Projects I was able to get lenses the perfect size from a Dollar Store insect viewer. The front lens was the unmodified "viewing" lens and the rear lens was made from the enclosed magnifying glass. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150824260-BZ2KDNEZHPKQH3NC4GZ7/ritona_old34.jpg Projects The sight adjustment knobs were cut from a 1" dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150824520-WOB69Y3I6TZE4F4FM7OO/ritona_old35.jpg Projects I cut posts from brass tubing that will also hide the knob attaching screw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150824870-27VWZWR7QGWNWKZ2E14W/ritona_old36.jpg Projects The final knobs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150824957-01OVKJHYDMLST7JA9QAC/ritona_old37.jpg Projects I cut the front and rear scope mount out of 1/4" poplar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150825387-HGB62M93VC76AXI6SSTK/ritona_old38.jpg Projects I cut each in half and inserted long bolts to attach them. The bottom bolt goes through the rail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150825564-FXGSVK95KP4S3I1BRNIE/ritona_old39.jpg Projects The final assembled rifle with a coat of primer (per client's request). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150825969-59FB2YSUAL8EWYIR7UYL/ritona_old40.jpg Projects The rifle is a massive 73" long! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150826252-ZDSKXZWDQU90SY7GUM4J/ritona_old41.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150826476-QG3OUTZ81DWXSLI3JSE2/ritona_old42.jpg Projects Detail of the scope. I forgot to add the lens on the small range finder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150827095-RZQCUPDRWTGFB0F01P20/ritona_old43.jpg Projects The folded bipod with added rubber feet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150827222-QCHJY5FI6TMA7UMPUX53/ritona_old44.jpg Projects The magazine is an open box so you have someplace to hide your weed...er...keys and ID. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150827793-ZITRO5M35LLU8801QS6X/ritona_old45.jpg Projects I had enough parts leftover from the commission to make a second rifle. I decided to make some modifications and paint it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150827800-93U0DQRS6J5K4MPIRYZI/ritona_old46.jpg Projects I made a moveable spring loaded bolt from an inner PVC pipe and a wooden dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150828387-DJI5BR5DR60IX7ERITFG/ritona_old47.jpg Projects I finished the magazine and added a fake bullet at the top. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150828749-Z6HTCNS4NHN4ISRT27M0/ritona_old48.jpg Projects I used real mounting rings to attach the scope. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150828852-YIWS120T7XZF6G7WJHM8/ritona_old49.jpg Projects After painting the rifle, I used banner adhesive vinyl to make the marking on the barrel and stock. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150829182-3CD80LGCIWHX1CNKYTOS/ritona_old50.jpg Projects The final piece...good enough to get you shot! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532150829306-ZLAGWVGU5MNQAV7NRI1E/ritona_old51.jpg Projects I've also made copies in navy blue to be a more literal translation of the anime. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108914239-C3XCEA07V24HOIJNPCLG/haseo_old_00.jpg Projects I was commissioned to make Haseo’s weapons from the the .hack series. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108914794-0J1EHXQQP5XGSL7Z5R8J/haseo_old_01.jpg Projects I cut the body of the weapons from 3/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108915867-M347RTPDUREWSUD98R6Q/haseo_old_02.jpg Projects The points were cut from 1/4″ poplar and then edged on the sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108916308-4CP48CTMZTX3Y9Z6KIXH/haseo_old_03.jpg Projects I cut a channel to house a 1/4″ steel rod that I hand bent to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108917795-3F4ZR7M5CPZYCRWAF0N3/haseo_old_04.jpg Projects I started to shape the bumps on the belt sander, rounding the outer edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108917921-2EKV8U375JB05QF3LW00/haseo_old_05.jpg Projects Using a sanding drum in a hand drill, I shaped the depressions. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108919431-0QEH14KG54V9MIWRZF29/haseo_old_06.jpg Projects Gradually moving toward the final shape… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108919753-FOS9T53ZFXLKOD7PFQP8/haseo_old_07.jpg Projects All major shaping done it’s time to sand! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108920886-ZOE51ZRND2ENCIAPDQL5/haseo_old_08.jpg Projects Both are sanded smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108921327-JCTAKRWNGNLKQQ1A5E7G/haseo_old_09.jpg Projects The points are glued in and the whole thing is primered. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108922141-UN65K5Y8B20BFL2Z3KM2/haseo_old_10.jpg Projects I glued on 1/2″ MDF pieces to support the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108922819-JCGEUPVSARC4QRSK63H2/haseo_old_11.jpg Projects The pommels and the guard rings were shaped on the lathe from MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108923508-Z9O1GYNVDQT3ZYIXVLTU/haseo_old_12.jpg Projects The master for the guards were carved from layered MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108923958-470KHA4QNNC7FUC7B226/haseo_old_13.jpg Projects I vacuum formed some .04 styrene for the detail on the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108924704-2UIEQX6K6KJ99896OQLR/haseo_old_14.jpg Projects I cut out each piece of piping and CA glued them to the master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108925637-YVSZ5QQTZE6OMSRKFGCL/haseo_old_15.jpg Projects With the guard ring glued in place the guard master is done. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108926284-D26UXHTKL1MPZ4CZLSYG/haseo_old_16.jpg Projects The back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108926845-D75Z71LSPEVV2A82DJAZ/haseo_old_17.jpg Projects I made a mold and cast two copies of the guard with resin plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108929541-ZATTQSMJCS08QGH94O5P/haseo_old_18.jpg Projects A test fitting of all the parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108929950-NRZ24HDI8SQCAH7AGOHU/haseo_old_19.jpg Projects The guards were sprayed with a gold base coat and then hand painted black and red. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108930809-I6UDVROPS158ZYIQZ37W/haseo_old_20.jpg Projects I left a section of raw MDF so the guard would have a better surface to epoxy to. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108931974-C1TOZJQGDRS876HJBIX8/haseo_old_21.jpg Projects I glued acrylic gems to silver-painted washers and then attached them to each side of the points. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108932543-CRU20H4CVIRBPYUR7YLM/haseo_old_22.jpg Projects The final props! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108935998-MSLZ80C4TVFM1X64WD9E/haseo_old_23.jpg Projects Guard detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532108933809-Z64UB846JPVG2HKYB3UV/haseo_old_24.jpg Projects The props in action at YoumaCon 2008 in Dearborn, Michigan! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977327230-B4SY29MS85IAE5PMH3DW/DMC01.jpg Projects Over the years, one of my more popular projects on the blog has been the Devil May Cry pistols, Ebony and Ivory. I was commissioned to build them again but the client dropped out. I decided to proceed since there seemed to be a demand for these. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977327529-H1MQLEAWAQWO4UA8WIB1/DMC02.jpg Projects I planned out the guns so they could be built using layers of laser-cut MDF. This would allow for maximum accuracy as well as the engraving on the barrels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977328488-7P8UG4QFUMKI7F7BO2SW/DMC03.jpg Projects A quick test fit of the parts shows how everything stacks. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977329491-VDDOTCDBHJFTLUIWRX0P/DMC04.jpg Projects I didn’t get the slide grips cut deep enough so I had to go back with a file to build depth. Afterward, I sealed and strengthened the area with shellac. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977329909-6H2DBY6L1DO5JXPKN4K1/DMC05.jpg Projects Since the laser only cuts perpendicularly to the wood, I had to bevel and round certain bits with sandpaper, files and the Dremel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977330558-I4ND77CRSN3BZ75X73V8/DMC06.jpg Projects I also inserted pegs and drilled holes in the opposite side so that the two halves would lock together like a real model. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977331176-QBJOET4PMD64JCRH9QAP/DMC07.jpg Projects With the body halves assembled and modified, I could seal them with shellac. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977334427-6I8F8PS9ASYM390VKU3D/DMC08.jpg Projects A coat of primer begins the long cleanup process. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977334792-ENPPVFMCF0892JPUNNCV/DMC09.jpg Projects A simple dump mold gives me plastic copies of all my parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977344962-TERVEC1D0BLC7WQWXACT/DMC20.jpg Projects I forgot to add the serrated edges on the hammers when I had them laser cut so I had to manually add them with a file. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977345292-W26EINMVH6407DPO64A8/DMC21.jpg Projects Ebony’s rear sight is a two-part adjustable piece that I just scratch build from wood and bits of plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977345842-7LDV3GJ5P7E1NK2ZZ4T1/DMC22.jpg Projects The “slam pads” on the base of the magazines were made from 1/2″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977347306-IWW6KAS919833Q9WTHJK/DMC24.jpg Projects The grips were made with wood as two flat panels and thicker wood to connect them in front. The pins keep everything in place while I work. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977347552-YAAMTXOWBTTPO36F8ICG/DMC25.jpg Projects Some work with the Dremel sander and the front of the grip takes shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977348155-ZCHICFPMANEJKGUI8SL2/DMC26.jpg Projects If this were a real gun, the grips would come in two halves and would be screwed to the grip. I built mine the same way and added pegs and holes so the halves could be easily lined up for glueing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977349349-VPPGEOCQ2E1DU4UUAUHZ/DMC28.jpg Projects To make the inset for the cameo, I traced my plans with a sheet of clear acetate and cut out the oval to make a template. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977349939-56Y3XTF6QSQQXCBV0U52/DMC29.jpg Projects I pegged the template in place and traced the oval. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977350379-RL71215Y9F1I4GGX0XR1/DMC30.jpg Projects I carved out the inserts with a Dremel rather bit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977356660-PO6YP3G8O7CDGY63B35E/DMC37.jpg Projects The finished masters ready for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977357748-X2ZCW3CYN0LZ5AFHHC1O/DMC38.jpg Projects After adding screws to the grips, I made a mold. Here you can see the resulting casts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977355339-CSHCYCQTYVZUTQLP79QB/DMC36.jpg Projects I needed round headed screws for the base of the grip and OF COURSE there was only one in my hardware bins. I guess I was too lazy to go to the hardware store to buy three more so I made a quick mold of the one in clay and dumped resin into it to make plastic copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977361128-8PS9XXONPTAMWU56HC9S/DMC40.jpg Projects The resulting mold. I pour a small amount of resin in the open mold to capture the outer detail before sealing it up and filling it up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977362465-7F2BBVZ3AKYIV8AITTTN/DMC41.jpg Projects The cast copies! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977364535-EW47U5QIEGUC9W1R99TI/DMC42.jpg Projects Test fit of the halves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977366061-BU7X7HP0EC2NMWRJWR0Y/DMC43.jpg Projects All the cast parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977366755-HDD3PQDYTE8AZUR3A8C1/DMC44.jpg Projects Brass pins allow the hammer and trigger to pivot. The hammer will have to be placed before the gun body is sealed up but the trigger can be inserted after the whole thing is done as the retaining pin passes through the body of the gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977368740-Y32XLN4K97JY7H3NIF35/DMC46.jpg Projects Ebony is painted with the Testors’ Metallizer Gun Metal and Ivory is painted a silver. In the foreground, two more castings have just come out of the molds. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977367510-128OPLA8O403VSY22OAB/DMC45.jpg Projects I applied some two-part epoxy and clamped the gun bodies to dry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977370593-MBPMF0CCTHK3WJY3422D/DMC48.jpg Projects The grips were painted with a base coat brown and then dry brushed wood grain was added. Once dry, I glued them to the pistols. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977371118-KF6TQYMKBQD9BPSWI554/DMC49.jpg Projects Small parts painted and glued on, screws on the grips painted silver and the engraving on the barrels painted gold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977373557-IA1D1F7UJ1MQAW7HLEYP/DMC53.jpg Projects The final step is to apply the cameos. I laser printed each portrait on label stock, trimmed them out and inserted them into the grip. The label was sealed with a spray acrylic enamel clear coat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977375547-XYS9P48SITI9S2RRLZV9/DMC55.jpg Projects The final guns! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977375640-2NE0O5OYHB1OI0X9RY66/DMC56.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977377136-CY3097FAB1K27JYZ0N8U/DMC57.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977378431-BMAF1P2JCP9O45J2YYM7/DMC58.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977380482-IBIE73DIKQWNCXSYRKGS/DMC59.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977382085-OKV6XFKT759XOGNOOAAX/DMC60.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977383785-G5WUFF9V4I0DWYXPG7KQ/DMC61.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977385977-75JP5Q7CKSDHK5405S6A/DMC62.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977387019-AJF0ZV26IWUPRFMBDUEO/DMC63.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977391217-CP2LZNPEMDYSB7YT58S5/DMC64.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977390457-84DJ6NJ0SSNKFJNDUZMJ/DMC65.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1531977392405-SQ79GPVUMN371J0D8U25/DMC66.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213617921-JRA5BLAAQJHX9SR3NOB7/swordgun01.jpg Projects I was commissioned to make Cornelia’s weapon from the anime series Code Geass: Lelouch of the Rebellion. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213621365-L1A06VUI8FIQNI0HURPE/swordgun02.jpg Projects The guard pieces were cut from 1/4″ poplar. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213621624-XGWF436URL1KIAK99LTB/swordgun03.jpg Projects The pieces were glued together and sanded smooth. I left a little on each end to attach to the grip and basket guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213626231-2EMPUXL7WW2MYW8VDFBZ/swordgun04.jpg Projects The grip was cut from 1/2″ MDF with 1/8 MDF grip plates. In order to later insert the trigger and other parts, I needed to be able to split it in half. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213626645-DLXUW9KVEEMLF3IBFP8C/swordgun05.jpg Projects The basket guard was made from four 1/2″ MDF sections. Each side’s parts were laminated together and then each half was lightly glued for shaping. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213634713-XCCUWY7LD4RUXERMAPLT/swordgun06.jpg Projects Using the belt sander and Dremel I started to shape the basket guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213634940-9SBDKEOLSVP340OFZVMG/swordgun07.jpg Projects After the rough shaping was done, I hand sanded it smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213638703-H9P3NJTRTPEC78IO6CN4/swordgun08.jpg Projects I used the Dremel to hollow out the back of the basket. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213643136-KTL0DAIIDXEBZUQQK9PY/swordgun10.jpg Projects To make the trim, I used an Xacto knife to trace the outline and then carved out the recessed areas. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213643343-ZTE2BYX763EBTOQWXYAU/swordgun11.jpg Projects The barrel was cut from a plain ol’ pine 2×4. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213647693-VS07IM92PFXO6PIDK4UJ/swordgun12.jpg Projects After the board was cut to width, I cut the two 45º bevels on top and then Dremeled out a slot for the front sight. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213648175-SHXIMGO1M9TTNHMXP8HD/swordgun13.jpg Projects I then cut a slot on the bottom for the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213651526-LNA5BBOOZYY0M81CHYST/swordgun14.jpg Projects The bottom 45º of the barrel were cut on the table saw (at great risk) leaving the last 5 inches to manually shape. Inserted is the .060 plastic for the blade that perfectly fits the kerf of my table saw! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213653969-G4TSKRW2WB32XHJ35I82/swordgun15.jpg Projects The plastic was then cut to shape. An edge was scraped using a pocket knife, as illustrated in my Spartan sword entry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213659860-P89OSMSCNIUL8NTJ83L3/swordgun16.jpg Projects The grips were shaped. sanded and trimmed as the basket guard was. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213668619-QBNA6DAW024K2FUSQ4XL/swordgun19.jpg Projects The completed barrel and basket guard! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213671271-2A8PHALAKMJBN7I8DL8I/swordgun20.jpg Projects I pried apart the basket guard halves in preparation for connecting it to the other parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213679425-KUHM8LVN4RH8YJRAPICU/swordgun21.jpg Projects I hollowed out a recess for the trigger to operate.The trigger was cut from plastic, swivels on a nail and pushed forward by an ink pen spring. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213680175-C4767VMM0PTY5N08W7EX/swordgun22.jpg Projects The final assembly. The cylindrical part of the receiver was lathed from pine leftover from the barrel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213684497-FTKM93CWDL1V3NCCR2H2/swordgun23.jpg Projects I used MDF to make a support for some some decorative plates that appear in front of the basket guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213692238-GJ4YVAG25ICW4E8VPI1T/swordgun24.jpg Projects The decorative plates were cut from .060 plastic with a trim cut from .040 plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213697861-2HY3N9V9HUARVKJI7Y7L/swordgun25.jpg Projects I picked up some mirror rosettes to use as a round element on the basket. I substituted an nail for the center screw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213697858-RGZL59YJPUU0G6R8S6ZI/swordgun26.jpg Projects I didn’t care for the way the block was looking co I made a MDF curved addition to make the visual transition to the barrel smoother. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213725024-SA00G3QE1H1S53WPCW6I/swordgun34.jpg Projects The final painted piece! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213710447-PD0DEGRCFECJQAKV7FB9/swordgun30.jpg Projects Detail of the basket area https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213716893-K8ANWSE69DA9LVRW1KL6/swordgun31.jpg Projects Muzzle detail. The barrel hole only extends 1″ inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213717310-8ZPM262VM5521ZCL3BC0/swordgun32.jpg Projects Detail of the pistol grip. I drilled a small hole in the butt post in case there was a need for a lanyard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213723186-91PCFB7TJ1FV3MERIR6R/swordgun33.jpg Projects The pistol in relation to a hand. Pretty comfy! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532213727140-U49NB9VVN9L6IB382IGI/swordgun35.jpg Projects The prop in the client’s hands. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210406216-W15C38FFGGE38T824QHE/tenchi_old00.jpg Projects I was commissioned to create the hilt of Tenchi sword from the anime series Tenchi Muyo! This weapon creates a lightsaber-like blade (which I will not be building!) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210406981-7UFL6K28Q7FW9CLT0JGU/tenchi_old01.jpg Projects After sizing my template to fit the wielder’s hand, I cut it out of 3/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210407508-FN0BRHX5TG69BLTQGTEH/tenchi_old02.jpg Projects With a combination of exacto blade and Dremel, I carved the pattern into the MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210408229-J5FBWJSIMR5GN3F1J369/tenchi_old03.jpg Projects I didn’t have any reference for the back so I extrapolated the front pattern to wrap around the other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210409102-1FGZOZRTVF3E2MC9EH4A/tenchi_old04.jpg Projects Once it was cleaned up I painted my base colors with acrylic paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210409521-CXIRUA8YZVXKAESUZ3Z9/tenchi_old05.jpg Projects The wood grain on the pommel was hand-painted to preserve an organic look. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210410562-P9LI8DLK1UQZ1CMH6VBN/tenchi_old06.jpg Projects I then took the base color and dusted back the lines. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210410876-FBFKJ1REPP5214LFX0HP/tenchi_old07.jpg Projects I added 11mm ruby acrylic gems to each side and applied a wash to bring out the details of the carving. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210412380-O1QCVKDGT88AVH5K4IKT/tenchi_old08.jpg Projects The final front view https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210412552-MV7CQH76OUOBNMXRAA87/tenchi_old09.jpg Projects The final back view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210413559-8FQTKY0H5ZQE4CIPCN5G/tenchi_old10.jpg Projects The prop in action! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210594563-9L7OF97T12YZ56H6E8B3/02.jpg Projects A few years later, I was commissioned to make a custom hilt for a wooden martial arts practice sword. I was able to get my original Tenchi hilt on loan from the original client to make the new one. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210596119-CMNXA4RSXSQ1ELLZ3J09/03.jpg Projects I cut off the guard and shaved down the hilt to reveal the tang. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210596497-I3Y61WVLPP0T4F4CSL3Z/04.jpg Projects Since the tang didn’t extend all the way through the hilt, I reinforced the grip with pieces of cherry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210598256-TXAPX86CR0KJ2XA2FD37/07.jpg Projects In order to make the hilt fit around the wood, I had to make the hilt thicker. I glued 1/8” basswood to each side to make the hilt 1/4” thicker. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210598576-T5M9Y96RU66GNBZOG5MU/08.jpg Projects I finished the edge, blending the basswood with the resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210598846-1303FVDDU1WADXKIJ825/09.jpg Projects After clamping the sides together, I rescribed the lines that crossed over from one side to the other. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210597163-FQNN76XND4PQH7FUCIIY/06.jpg Projects I also carved the wood grain into the pommel rather than just painting it on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210600043-TMAUGXXJWM6JUKMI816X/10.jpg Projects The blade had some distortion and damage from use, so I sanded a fresh edge and filled any nicks. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210600850-CTUJMEXSI6YXYDMJB28W/11.jpg Projects After the resin halves were completed, I placed them in a mold box and applied a thinned coat of Smooth-On MoldMax Stroke to capture detail. Once that cured, I applied a thick coat of Stoke to build the mold walls. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210601675-DOGBXPWOMP6H2C42SGFG/12.jpg Projects The demolded masters! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210604248-XHZENBC6W214B8OC641T/15.jpg Projects I used the cutting attachment on my Dremel as a router to carve a slot in both halves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210605573-VBOS77NHHBNN6RHRGOBL/17.jpg Projects I used two-part epoxy to glue the blade inside the two halves. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210605703-E7GINB8R4KWK6LINFSEX/18.jpg Projects A fresh coat of primer on both hilts in preparation for final painting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210609828-S0K4UHK23ME84ZAPP8X7/19.jpg Projects The new Tenchi hilt (left) compared to the original. The new grip is 1” thick and feels like a proper sword grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210610366-Q28XGGTRP37C9A3RJPQ3/20.jpg Projects The other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210610846-RPFG106ZN9F9R2L4EPTB/21.jpg Projects Detail to better show the thickness difference. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210611199-1USNVH2ZG6877WEUHEDB/22.jpg Projects Detail view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532210611658-Z6Q140I2C7WI26ZKSNSS/23.jpg Projects The blade in the final Tenchi grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288091756-UGVD58HB9QUMJIYIB63C/Tarakudo-0001.jpg Projects Making the Jackie Chan Adventures oni masks has been a project that I wanted to build for a long time. I decided to start with the mask of Tarakudo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288866323-501VU7HBGPPSDGT5H2EZ/Tarakudo-0001a.jpg Projects Based on screen captures from the show, I drew up plans in Illustrator. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288091937-EQAS5PQ34PD8DZF5GN8P/Tarakudo-0002.jpg Projects I pulled the plans into Strata3D and modeled the mask. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288096015-1WZOLRMAJEVVXNZIS2LN/Tarakudo-0003.jpg Projects The mask was too big to print out all at once but the printing software allowed me to cut it into sections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288097215-0TQ6BGTOFQYS3D4I64CG/Tarakudo-0004.jpg Projects All the printed parts glued together and the seams filled with putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288100687-I75ITUW8LAU7C9COAWFV/Tarakudo-0005.jpg Projects A coat of primer and much sanding later, the mask is ready for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288106257-X45UAIK7XMMPX1U3GJPV/Tarakudo-0007.jpg Projects After casting a copy, I painted the base coat in Rustoleum Satin Fire Orange (# 263149) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288108933-SW1E1Y9CP1BN80UQPSN2/Tarakudo-0008.jpg Projects I cast the “hair” as separate resin pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288111985-E4CC31Y8OAONXDV6T90P/Tarakudo-0009.jpg Projects The black areas and teeth painted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288113958-IIU00KQMRIPK0BKK7MCG/Tarakudo-0010.jpg Projects I glued on the hair but to make sure it didn’t come off, I put some screws through the back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288116816-ILSW46W3IZNO0TSTJ7L1/Tarakudo-0011.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532288870608-7WU2ACERRPRHGEIOOMFL/Tarakudo-0013.jpg Projects It’s pretty comfy to wear and it has good visibility. Now to summon my Shadowkhan…to help sand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497639051-5Y63TJPSSGPC0I36BCJS/01.jpg Projects I was commissioned to make Marth’s sword and scabbard from the video game Super Smash Bros Brawl. Timing was short so there were a few short cuts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497639069-TKXTDST7ADOIRWNF5ID3/02.jpg Projects I started with the blade by cutting a groove through two sheets of 1/4″ poplar to house a 5/16″ steel rod. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497639562-670CNPGC7AZACUCIRFZP/03.jpg Projects I glued the wood together around the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497639664-WLGE7O31S6K8DNZFLFLS/04.jpg Projects I cut the outer layer of the blade from two more pieces of poplar, including the inner slot. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497640078-NJ8FA8MNO0DIZM55VCY2/05.jpg Projects I glued the outer layers around the inner layers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497640123-VVW3Z9MR7Z26S4CMU17P/06.jpg Projects Here you can see how the layers fit together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497640460-L42JJ5GY1G4DEIV5UGJX/07.jpg Projects With some tricky table saw work, I was able to cut the bevels on the blade leaving a 1/8 edge. And I still have all my fingers! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497640595-9KG8LWNN27YVJT5EVPU6/08.jpg Projects The drawings show the sword with a flat diamond at the tip but that would’ve made the point much stubbier. I decided to keep the profile accurate and bevel the tip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497641092-6QFK2QYN8C1WOH3RMPR5/09.jpg Projects I lathed the grip from a pine dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497641224-SC1MP8G8VAQUHDHP510D/10.jpg Projects The cross guard was cut from several thicknesses of MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497641580-CVD50W5NKBB7F5B6J1QA/11.jpg Projects The MDF was shaped with belt sander, dremel and file to get the appropriate facets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497641882-VY6R60WIEJYSZGLF2X1Y/12.jpg Projects I cut the pommel piece from two layers of MDF and a channel for the rod. The facets were shaped on a belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497642073-5ACZHI9FGOHRAUHXWDWP/13.jpg Projects I used my mini-vacformer to shape .09 plastic around each half. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497642229-L6PLCVENPJN0MUTRRXMR/14.jpg Projects I then cut the raised trim from the plastic shells. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497642610-CP46BYTGQOR5KXSVR7XV/15.jpg Projects The finished pommel, all puttied and coated in primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497642789-PIHFRH0NOQEE9NL8C3RI/16.jpg Projects Since I didn’t have time for drying, I painted the sword with acrylic paints. I found a great gold that looks as good as the enamel metallics! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497643973-F7O4W1EA1R9YXG637OER/17.jpg Projects For the pommel gems, I cut the shapes from 1/4″ green acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497644121-GOMRQOOV06XQ1ENGWKFD/18.jpg Projects I shaped it into a dome with the belt sander and Dremel… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497644812-M1VUWS9VW255NWCPER75/19.jpg Projects …until finally buffing the gem to a glossy shine! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497646579-THHQ7TAYV3BGYBRDJKJ6/20.jpg Projects I used the same process for the large hilt gem, making it from laminated red acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497647966-MHVVJQNZ7KPXWJAQAF3N/21.jpg Projects Here are all the primer coated pieces together for a test fit. Obviously this was before the painting, but it didn’t make sense to reveal it earlier. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497649725-XGMGAXRETE2TIVQJ43YE/22.jpg Projects With the sword done, I could start on the scabbard. I cut the outer shape from MDF, leaving room for a lining, and glued the walls. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497650200-073D4L0OSQD1AKPTH8OU/23.jpg Projects I used the scrap pieces from cutting the blade angle to make the inside fit better. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497650775-3J2SH8G6ZDO0CN7ZDRDM/24.jpg Projects The box lid with the edges rounded with a router. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497651188-9HVP9XRAGU21V9B34M13/25.jpg Projects The tip of the scabbard was made from 1/8 MDF glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497651653-1NW1DGKVH2LRLVLNRHPV/26.jpg Projects Time allowing, I might have made the design inset but glueing thin plastic to the surface had nearly the same appearance. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497651716-EYGIJ0LX92DYH8KDEE9R/27.jpg Projects I heat formed thick plastic bands around the opening. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497652039-1F7WRLD53GEBF37HPAVW/28.jpg Projects More heat formed details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497652134-OZEFIGKEADKP9JFOWDKO/29.jpg Projects Since the scabbard need to be wearable, I needed a metal “belt loop”. I had an old hard drive sled that would work. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497653683-JSYPBDE1DTX7EBJ13G76/30.jpg Projects I cut off a piece that had the right shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497653790-U70JUR4W8AWA7N5PHQ6Z/31.jpg Projects A bit of wresting over a vise and I’ve got a 1-1/2″ loop! It was attached with 1/4″ screw posts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497654127-MYORA7AYVC74LW9S65X4/32.jpg Projects Here is is in place on the back of the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497654330-IDRD3CX36RFANJ64MC17/33.jpg Projects With the bracket glued in, I glued in the black felt lining. The box could then be glued together and assembled. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497654834-JPEFBRG0JAK58EAW7JP6/34.jpg Projects Here is the final scabbard. The blue and gold details were cut out of thin plastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497655133-9IOD6E0Q7NNPDY66SKJW/35.jpg Projects The final sword https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497836273-7XQNZ66AI6F0MDGCUILY/02.jpg Projects Later, I was commissioned to make another Marth sword, so I was able to make a few refinements to the design. Instead of vacforming a shell over the pommel, I decided to build the bands from strips of styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497836856-JX93UTXPHFR5MKDD7MEQ/03.jpg Projects I made the guard a bit thinner than before so that the “arms” had a more pleasing edge https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497836934-P0LLIJULWU66O4G90YO3/04.jpg Projects The scabbard end cap was made from thick styrene with holes cut into it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497837194-FXN3ONHHZW9JRAHKOJ9A/05.jpg Projects Sides were added to make a box. The holes were backed with a very thin styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497837377-LP4SI3GDGGOHQY4Y10LI/06.jpg Projects I wanted to make the design on the scabbard with more relief so I made a master from thicker styrene and used scrapbooking brads for the rivets https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497837541-BAQB933Y4S26L6FTWLW2/07.jpg Projects I made a mold of the master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497837804-VSAO2T8CCIR7DL06YA5L/08.jpg Projects I then cast copies of the master out of resin to be glued to the scabbard. The one on the left is the copy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497837978-AE29ECNJASYPMVDWH7IC/09.jpg Projects The painted design. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497838215-T9ZW6B7NXF1UNMUZK2EM/10.jpg Projects The final painted sword https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497838360-14U0YCOQYS9Y9FZDP2G8/11.jpg Projects The final sword in the completed scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497838741-VSA25T7EKQ5Q5VFRTWDN/12.jpg Projects I painted the belt loop to match the surrounding details so that it would blend in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532497838806-JI1NFOFEQQGGDHX0JH4M/13.jpg Projects The final end cap. It is painted a slightly more yellow version of gold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586042069-TLBOYCJTW1IO84H156GG/01.jpg Projects Penelo is one of the playable characters in the video game Final Fantasy XII. I was commissioned to create her magical staff. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586042218-FSGMS1Q25A4SCRFLSSW2/02.jpg Projects I cut out the blade shape out of 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586042746-ELK7GQQMR5NHW7LJVXKK/03.jpg Projects The edging was cut out of 1/8″ MDF and glued on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586042821-PO6J3YCKJSC1TCA5UN4M/04.jpg Projects The end caps were also cut from 1/4″ MDF. Once they were glued on, the entire blade was sealed with shellac and seams filled with putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586043328-0ZLJBYZGT1KNBJGK5AG4/05.jpg Projects The part of the staff that connects to the blade was lathed from 1-1/4″ oak dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586043538-5558YK64YIBSBQ7OA58J/06.jpg Projects The end cap was cut off the dowel to allow it to fit around the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586043663-G6HP5ISBTF0IPZI6FRP8/07.jpg Projects I cut a slot in the dowel on the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586044151-K2CS2K48EG6Y26C1I6GC/08.jpg Projects The head dowel with blade inserted. 1/8″ MDF was later inserted into the gap between dowel and blade inset. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586044251-CXIF4UAQI5GBMOK9G15A/09.jpg Projects To attach the head and base to the staff, I used threaded inserts. The final piece will now break down into three pieces for easy transportation. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586044643-12DVYKC3MK844VPAFK4E/10.jpg Projects The blade was first sprayed with a base coat of silver and then masked off to paint the gold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586044745-E2AUQRGDSTT5XUYGHBW3/11.jpg Projects The base of the staff was also lathed from a 1-1/4″ oak dowel https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586045190-1OBOJPGIMES08FPO59O5/12.jpg Projects I ordered a bell from a medical supply company and disassembled it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586045296-F2L1ZXUWHNZYWPVYNVZE/13.jpg Projects The striker was replaced by a wooden bead on a threaded rod. I painted the bell and strung beads on a length of cotton twine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586045613-N5M4I75SJ3E5B0TOY4R0/14.jpg Projects The bell assembly was attached to two elastic hair ties. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586046100-EXBJU6MIBKCDWHF6JJM3/15.jpg Projects I doubled up the elastic ties and slid them over the tip of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586046657-ZVYCT6W4AB71PCMNTK4O/16.jpg Projects To attach the beads to the blade I made grommets from 1/8″ rivets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586046666-NUGEKZG15II7WAJ4GAZE/17.jpg Projects I drilled holes into the blade and glued the grommets into them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586047850-I0J38ITNL5Q1SOQEWTR8/18.jpg Projects The last touch was to wrap the bottom of the staff with a faux suede. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586048229-S9Y2D4SDBHLT2SS3MJO6/19.jpg Projects The final staff is well over 6′ tall! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586311618-A6RJVLSCWDSQCPOZMH10/pullo_old01.jpg Projects I love the TV series “Rome” and decided to make a copy of Titus Pullo’s knife. It looks like a pugio but considering how crude it is, I suspect Pullo lifted it off a dead Gaul. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586311745-USHKRE408HJV4G2LSYD0/pullo_old02.jpg Projects I used layers of 1/4″ MDF. Two layers for the blade and two for the grip thickness. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586312244-4BUKTSLB4XCQ3L4FDLN0/pullo_old03.jpg Projects I rounded the grips with the Dremel and glued them on each side of the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586312315-59OEEGRM5RI7FMMVBAUS/pullo_old04.jpg Projects After gluing the blade halves together, I shaped the blade edges on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586313048-0C7TGMBTCT26LPO5PGLC/pullo_old05.jpg Projects I coated the MDF with shellac and puttied up holes and gaps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586313156-XJJ8PGP3QCM605I66OR8/pullo_old06.jpg Projects I painted the wood grip with a base coat of black with brown highlights. The blade was sprayed with a Krylon Chrome. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586313509-34PF1XPKUNRFDRS4PNS9/pullo_old07.jpg Projects I wound the handle with a 1/4″ strip of leather, trying to capture the spirit of the original. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532586313762-CY6A9J45SKQT3Q5QLHWJ/pullo_old08.jpg Projects The final knife! The wide blade looks like it would cause some real damage! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671600627-0UWUA8EFOJMJ43Y9WNGO/shinken_old_00.jpg Projects I was commissioned to make two of the Shinken (or Divine Sword). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671600631-5UKIYTT349G9SW00AJJD/shinken_old_01.jpg Projects Since I had to build two identical swords, I needed to make one master, make molds and cast plastic resin copies. The sword is over 59″ long and very thin so it would need a reinforcing core within. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671601240-ZU5O7PNIU7AE7NX4TN9J/shinken_old_02.jpg Projects I had a friend weld a 5/16″ steel rod to a 3-16″ x 3/4″” steel bar. I planned to make half the blade and guard cast cast copies to glue together around the steel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671601368-HZ99T2ET0APNSOK7G2JK/shinken_old_03.jpg Projects I sculpted 1/2 of the guard from clay. I worked on a mirror thinking that it would give me a better view of the complete guard. I think it was too flat to make much of a difference, though. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671601856-TDP5OM3N7FAHAJM9DPWW/shinken_old_04.jpg Projects I made half of the blade from 1/4″ Poplar and glued it to a sheet of MDF. A resin copy of the hilt was also glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671601931-UP0XK6K1MTMIFRGXIN2M/shinken_old_05.jpg Projects I drew a grid on the MDF to make sure the half would be symmetrical. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671602760-YF8YWFNL4CGU5KJWTJBD/shinken_old_08.jpg Projects After I cleaned up all the flaws with putty and primer, I made a silicone mold with a plaster jacket. The next day I slush cast two halves with plastic resin. I reinforced the resin with chopped fiberglass mat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671603419-R1DBOGRA6Y6JFEBYPLCP/shinken_old_11.jpg Projects I used a trim router to cut a channel in each half to make room for the steel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671603775-LHQYL9LQ3WRZ5II8251V/shinken_old_12.jpg Projects I mixed up a small amount of resin to glue the steel into the channel and then the two sides together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671604223-LEN034DVZDB1NTVNQFZK/shinken_old_14.jpg Projects To fabricate the ring around the star at the pommel, I inserted one PVC pipe inside another and cast resin between them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671604343-2M1AC7SJBHFD8QS94POH/shinken_old_15.jpg Projects The star was made from 1/4″ square styrene rods. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671604725-PXPLMJUSKDJAQZ805IVS/shinken_old_16.jpg Projects The master (in grey) and two cast resin copies. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671602412-P4NYLTVNR7Z9Q5LQBBRU/shinken_old_07.jpg Projects A thin rail runs down the center of the blade from the hilt. I laminated 2 layers of styrene and dremeled the characters into the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671603900-VWQVROISKMSJAOEZQT3D/shinken_old_13.jpg Projects The grip was lathed out of pine stock. I then sealed it with gloss black paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671606624-ONKMAGNLU2E7CH2ER1CI/shinken_old_24.jpg Projects I cut the lathed grip master into its components and cast them in silicone rubber. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671607010-CAN49MOJACYB5GPK3BO2/shinken_old_25.jpg Projects I inserted brass tubing into the mold and cast plastic resin around them https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671607196-EIX8178O9KPY41XNN33V/shinken_old_26.jpg Projects The cast grips. Now to trim off the extra tubing and sand down the rough edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671605212-U6EU78UO3VGFSOMK0820/shinken_old_18.jpg Projects To make the basket guard, I glued together 4 layers of MDF. I then shaped it on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671605327-NTDKGOW1URFW8DDM83JJ/shinken_old_19.jpg Projects I used a Dremel to carve some of the surface detail into the guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671605509-UPR9VOQ4HOVY07XTU3LT/shinken_old_20.jpg Projects To make the shield, I heated a piece of styrene with a heat gun and molded it to fit. I attached it with Bondo and carved the edge scallops into the shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671605962-8OHOEM4YI8TW3IUB1PFO/shinken_old_21.jpg Projects I heat formed some more styrene to fit the shield and cut two pieces of trim. After they were attached, I Dremeled the characters into the styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671606063-G2LIT6VUSQGPDI8071HA/shinken_old_22.jpg Projects The completed and primered Basket Guard. I made a silicone mold from this. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671606471-3I46FKV3GD9U60M923NK/shinken_old_23.jpg Projects I slush cast resin in the mold to make a hollow basket guard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671607541-2P2SRE0XVK5KYOJ5P83W/shinken_old_27.jpg Projects Here are all the pieces in a quick test fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671607645-PHT8N1DNZPIZQ2ZO93LI/shinken_old_28.jpg Projects The grips are wrapped in a purple thread. To simulate this, I picked up some cotton twine and a box of Rit dye. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671608103-YH1K1NNY2OQD9JBRGX8B/shinken_old_29.jpg Projects I did a quick test wind to find out how much it would take. The answer?….25 feet! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671608193-R29TCL7F9MDJLFH855TG/shinken_old_30.jpg Projects I notched the end at an angle and CA glued the end. I coated the grip with Elmer’s wood glue and started winding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671608589-6OAFQD9CXSU3WHBNKA90/shinken_old_31.jpg Projects I painted the blades with a gloss black to show any last flaws and to act as a base coat for the metallic paint and then applied a Krylon Chrome paint for the blade. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671608641-KUQBUQIXO37UOWM93SRD/shinken_old_32.jpg Projects I masked off the silver and painted the hilt with a Krylon gold leaf paint. The sword was then coated with a protective top coat of Future. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671610497-F80BAJUBQKA344EQZIZ9/shinken_old_39.jpg Projects The sword features a red hemispherical gem on either side of the hilt. I cut a disk from 1/4″ red acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671610813-HH73WOEUGG8A8ZW4V1DE/shinken_old_40.jpg Projects I used a Dremel sanding drum to shape the dome. Once it was sanded, I hit it with a propane torch to glass over the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671611106-U1IIFRP4HOHIX5QWOTI5/shinken_old_41.jpg Projects Here is the gem in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671611275-1FVMBEIIAAUIPUTLDT6V/shinken_old_42.jpg Projects I inserted a bit of threaded rod into the bead between the grips. One end of the basket will attach here. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671609523-GT5K26LM34P0ZO7RMUU7/shinken_old_35.jpg Projects The other end of the guard attaches to either side of the hilt. I attached these with two small brass nails. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671608960-PJ7Z5SIDLAM6LCIDEY64/shinken_old_33.jpg Projects The final assembled swords. They are REALLY long (59″)! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671609179-HIE4JYMFXE4GG03H1EP3/shinken_old_34.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671611724-UT78LRFFVSYR2S0UVE8P/shinken_old_43.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532671610293-05LBBRA60M1KD0DN5JOZ/shinken_old_38.jpg Projects The swords in action at the 2008 SakuraCon in Seattle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755605981-HDYNICT2OTMDVJVOZ3SY/hoplite1.jpg Projects After reading Frank Miller’s “300”, I became interested in the ancient Spartans. I based my pattern on actual spartan swords from museum collections, not the movie. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755497346-KPU8WR63SGSR8ZM1TCKD/1Inset.JPG Projects I cut out three 3mm sheets of plastic based on two photos of actual swords. Clamping them together, they still had too much flex. I got a piece of flat 3mm steel (3/4″ wide) and cut out a channel in the inner layers. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755520628-C0Q2PMWUBPKRBUQ3FSIX/2Laminate.JPG Projects I added two more shaped layers to build up what was described in my research as a “diamond profile”. On retrospect, I should have used full blade width layers as the shaped ones caused gaps that had to be puttied later. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755526218-GYL95HYSVGN2J39FAG8V/8KnifeBevel.JPG Projects I used the long blade from my Swiss Army knife to shave a blade edge on the sword. Hold the knife’s edge PERPENDICULAR to the surface of the plastic and you can shave the plastic into shape. This also works as a alternative to rough sanding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755528584-1HFBMZSIMQQF6N6LD7TH/9Putty.JPG Projects Next comes the boring part where you fill all holes and imperfections with model putty. Be prepared to apply multiple coats and spend some time sanding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755583598-6EIPH8VQ2DJ47ARQWDV3/14PommelParts.JPG Projects The pommel was constructed by cutting elliptical disks of different sizes with a rectangular hole. The “cap” I made separately to make it easier to get a file into the hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755551266-7HB4KFBYDNPC2ELB8BN1/11Handguard.JPG Projects The hand guard was constructed as a box which fit over cross members that were cut as part of the sword body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755603285-1RXIIP5A20A79LFW83AA/18SandGrips.JPG Projects The grips were cut out of 1/4″ walnut and Dremel sanded to shape. Note the tabs at either end to tuck into the pommel and hand guard. I then used some stain to bring out the grain and seal the wood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755595410-PBO8G5Y9WS37KVFPOD7A/19Sandblade.jpg Projects After painting, all the pieces were glued on completing my Spartan Hoplite Xiphos! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755599993-T01AIMMPSZBEP78YO4MP/21Final-Blade.jpg Projects The final sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755604687-75ZHQ98KE1EYR0SYZGKL/23Final-Hilt.jpg Projects Detail of the hilt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532755606128-3K90M0FPI49LA6M70U98/24InHand.jpg Projects It’s a short grip but comfortable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756402462-7VTU63VIZVMOI8FV3E1P/kachina_old_01.jpg Projects I saw a bunch of these at a local museum, and thought how much some of them looked like action figures. Perhaps “a long time ago” a Hopi fella happened to spot a certain intergalactic bounty hunter apprehending his prey, and decided to carve a Kachina of this obviously supernatural vision. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756402557-GFIJVQK1CE4OW7ULP6I1/kachina_old_02.jpg Projects I had no source for Cottonwood Root so I decided to carve mine out of 4″ x 4″ x 8″ Basswood. In order to maximize the size of the figure, I planned to carve the arms and rocketpack separately. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756403027-5147JL3WGT0PZAG7YG6T/kachina_old_03.jpg Projects The first step was to cut of any excess wood (saved for arms and pack) and draw the rough figure for front and side profiles. I used razor and hack saws to carve the rough silouhettes for both profiles. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756403070-GH69ZLMA5PMQMOI1T17P/kachina_old_04.jpg Projects I used scalpel tip X-Acto blades to start carving away the excess wood. The curved blades cut easily through the wood without crushing the grain as a straight blade would. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756403549-W2Y9Y20ZE7I88U0N990Z/kachina_old_05.jpg Projects The head is better defined. I want to carve enough away to make sure of my proportion but not so much that I weaken the figure or prematurely remove a piece I need. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756403637-4G0I3QMQZTAJ93LLE4IG/kachina_old_06.jpg Projects More detail on the legs and it was this point that I decided to leave the base looking like rock. it just started to look that way all by itself. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756404083-993ZNC1TFZJ4LT69IN88/kachina_old_07.jpg Projects Starting to define leg details like pouches and knees. STILL working on the base! The base is pretty much done and I’m happy with the basic proportions. Now to add details without getting TOO detailed. My first mistake. I cut off too much of the right toe so I decided to angle the foot down on a slope of the base. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756404129-YLFWRL97KR54BJA6ASOK/kachina_old_08.jpg Projects All details filled in and sanded. You can see the new foot position here. I think it actually makes the figure a bit more dynamic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756404754-BW0F628VPFBY7RC4UTWN/kachina_old_09.jpg Projects The left arm carved from one of the scraps. It was difficult to find a piece with the grain running in the right direction. If it ran perpendicular to the arm, it would be weak. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756404854-VXA3ROSXJBFHMHJURRYR/kachina_old_10.jpg Projects Right arm with pistol grip. I wanted to make the gun part of this piece but I had trouble with the geometry so I had to settle on adding it later. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756405387-D30H9XYQ3MCX6EKUEXXB/kachina_old_11.jpg Projects The gun added to the arm https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756405562-H9F4HVOLIYXMU30JIKFZ/kachina_old_12.jpg Projects The shoulder stock was the part that gave me fits on the first attempt. It was much easier to do in sections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756406072-CPWEYK7C6ZZZWZKJDAQW/kachina_old_13.jpg Projects The rocket pack was carved from Basswood but I used dowels for the cylindrical parts. the nozzles were attached with aluminum rods. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756406112-0KX0DYWSVBS5WJVWT3CU/kachina_old_14.jpg Projects The belt pouches were carved separately so they could show motion. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756406463-8WXPQARJD0X4061W9OBT/kachina_old_15.jpg Projects I coated the entire figure in shellac which seals the wood and brings out the grain. Since the wood looked so good, I decided to only paint parts that were NOT representing fabric (or the ground). I sanded a flat spot on the back to allow easy attaching of the rocketpack. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756406610-VPQGKWKQ6PB30V5L3YBA/kachina_old_16.jpg Projects Kachina figures traditionally use cloth, feathers and natural materials to complete the figure. For Boba’s cape, I cut a piece of bandana and distressed it on the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532756409005-YA775G7SDF353B79X79T/kachina_old_17.gif Projects All assembled! I used plastic coated wire for the hoses going to the gauntlets and the helmet “antenna” is a small piece of wood attached with a steel rod. My original goal was to make the Kachina using traditional methods (i.e. no power tools) and stylize the details through Hopi eyes. Unfortunately, Boba was also filtered through the eyes of a 21st Century geek so he’s probably not stylized enough….oh well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824919509-6SG21QIZ10CXRPMMK1L3/sauron_helm_old00.jpg Projects One of my favorite characters from the Lord of the Rings films was Sauron. My dream project is a full suit of his armor…which I will get to building…eventually. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824919618-3S9OIAE8ON6GHGMUWBPO/sauron_helm_old01.jpg Projects United cutlery came out with an official replica of his helmet, which I bought. It’s an amazing piece but it differs from the film prop in a few ways. First of all it seems to be about 15% too big…you look like a bobblehead wearing it. It is also extremely heavy so it’s not a piece you want to be wearing for any extended time. Using this as reference, I could make a properly sized version for myself. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824920166-HLSJO06I3EQMMDLSXJAS/sauron_helm_old02.jpg Projects Working on the plaster casting of my head, I started applying clay to rough out the proportions. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824920380-MRE4KB7W0K7KYXQJ6QRY/sauron_helm_old03.jpg Projects I lightly scribed the side details and started to rough in the the top of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824920875-E1BKUOX79SHPK80KTIU1/sauron_helm_old04.jpg Projects Working from the center, built the first layers around the face. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824920986-539S1XZ5KF1F1V19HD9I/sauron_helm_old05.jpg Projects The second layer… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824921560-DZKA1CI6FZRXADADQONA/sauron_helm_old06.jpg Projects And a third… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824921647-RI3B2P8L1EEM9HPHLYH6/sauron_helm_old07.jpg Projects And a fourth… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824922316-3DXZQ9VIBZB83X0YA6JK/sauron_helm_old08.jpg Projects And finally the back piece that leads up to the back spike. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824922501-HV0QQ8GIBEF7Z3MAT503/sauron_helm_old09.jpg Projects The back of the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824922828-TFHS2N49ADIFWEYFXLW7/sauron_helm_old10.jpg Projects The replica helmet had a stone-like texture to it. To duplicate it, I applied some silicone to a big rock to make some stamps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824923014-JB2PIQZCYJ6208164TDN/sauron_helm_old11.jpg Projects I stamped the texture to the helmet and scribed in some of the runes around the nose holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824923619-ZRXXYZ5O5VOV2KBLKJRX/sauron_helm_old12.jpg Projects The final textured helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824923485-A53T5WWI5GI7OUYXHWC1/sauron_helm_old13.jpg Projects I used clear plastic mold dividers to separate the two halves for molding. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824923990-EO70ODGGUFV9UVZKIGYJ/sauron_helm_old14.jpg Projects I was short on cash at the time I made this so I made a waste mold out of plaster. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824924285-AQIQYJJOR2C2YVMRDTJA/sauron_helm_old15.jpg Projects The left half of the mold removed. You can see how much clay was used to form the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824924510-GH384ANIIPYJRJMX3FXL/sauron_helm_old16.jpg Projects I slush cast resin into the halves. One the sides were built up enough, I put the sides together to slush cast the seam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824924863-CNISP4GAWTKO8QXYFZYI/sauron_helm_old17.jpg Projects The demolded resin helmet. This method is risky as the mold is destroyed as well as your clay original. It’s cheap to do but you could wind up with nothing at any stage! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824925037-ZLVIOZ2N4U1L34GKSFE9/sauron_helm_old18.jpg Projects Looking at stills from the Fellowship of the Ring, I saw that the film armor had a smoother finish with crisp, clean edges. I sanded down the surfaces of the helmet leaving little bits of corrosion. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824925826-QU6XLHVVRAU8QQHVPEAW/sauron_helm_old19.jpg Projects I sanded off the scrollwork on the top of the head as I couldn’t sculpt it clean enough. I remade the design in epoxy putty which would be later sanded for a flat surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824926065-SZKTWONGYOI5NVLX0WK3/sauron_helm_old20.jpg Projects I made the spikes from styrene filled with resin https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824926420-X5E8NSFOUEVJ7CUHDHW0/sauron_helm_old21.jpg Projects I attached the spikes with epoxy putty and dowels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824926638-49E4FKS8HDXMTXW4I79Q/sauron_helm_old22.jpg Projects A primer coat to test the seams and detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824926887-3QNZXR0B881SEAFN0VZ1/sauron_helm_old23.jpg Projects Detail shot of the top of the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824927195-EEJMDKNLLZIYD27504U4/sauron_helm_old24.jpg Projects I sculpted the back spike in clay and made a quickie silicone mold for a resin copy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824927566-VOXV30ZCY1KWUXFUF5RN/sauron_helm_old25.jpg Projects I penciled in the runes on all the panels of the helmet. I used photo reference for as much as I could and made up the rest https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824928121-V4Q8YF2UEEDBJ685480X/sauron_helm_old26.jpg Projects After some experimentation, I went back to the way I made ruins on my old Halloween costume: Puffy Paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824928179-M0IZ71WECL1SKWBO1WN9/sauron_helm_old27.jpg Projects Primer over the puffy paint blends it all together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824928579-KTWGRKRLNABOTMW4YP62/sauron_helm_old28.jpg Projects Runes on the back as well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824928888-2SL58TPFUGZSTV6ZYKTX/sauron_helm_old29.jpg Projects A base coat of metallic paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824929202-RQP94LEC0XMEBQ2ZYJ8Y/sauron_helm_old30.jpg Projects To cover my eyes while wearing the helmet, I heat formed some styrene and pressed it into the inside of the mask. I trimmed out the eye and nose holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824929385-TCBASVVMHWTKE50D4450/sauron_helm_old31.jpg Projects I stretched black nylons over the styrene and hot glued them to the back of the plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824929656-T79XEAGI5510GOQDOGEK/sauron_helm_old32.jpg Projects This part was glued into the helmet. I can see and breathe perfectly but no one can see in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824929836-4GB85E51557Q7VP420U6/sauron_helm_old33.jpg Projects The metallic paint was given a black wash to prong out detail and knock down the shine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824930260-41OKLCACTQD1UR09IDSO/sauron_helm_old34.jpg Projects Detail shots of the face. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824930476-NU0XT9CX5WDIK9AI5M2M/sauron_helm_old35.jpg Projects Back view and detail on the top scrollwork. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532824930815-2S7Q5CVTIWBTEKN3CHA1/sauron_helm_old36.jpg Projects Side view. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825662513-COTLJ8Q92R9ZPTS0CUA3/boromir_shield_old_01.jpg Projects United Cutlery planned an official replica of Boromir’s shield but went out of business before it could be made. I was really looking forward to getting one so I’ll make one myself. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825662866-641HMSRTLHJ5WQLK2NFB/boromir_shield_old_02.jpg Projects The shield was constructed out of two 3/4″ MDF pieces, cut to 27″ square. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825663731-2JGEVX0P164T3FKVMK34/boromir_shield_old_03.jpg Projects I cut the circles with a jigsaw and glued the two pieces together. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825664384-AFZZ573EK5A0V2939H81/boromir_shield_old_04.jpg Projects My cheap-o lathe only turns over the bed but it has a disk sander on the outside. I suspect that this was stupidly dangerous BUT I took the sanding disk off the machine, drilled holes in it and mounted the MDF to the plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825665122-HP9XE0LH4L6LYTSYTGP0/boromir_shield_old_05.jpg Projects I started turning the outside of the shield first. The MDF weighed about 20 lbs. I spun it by hand to get it going to take stress off the motor but once it got going at top speed (of the lathe’s lowest setting) the weight made the ENTIRE LATHE wobble and shake! I used a foot switch to kick off the power and then lathed like crazy while it slowed down. I expected at any second the whole thing would come flying apart, sending heavy chunks of MDF and broken lathe in all directions! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825665586-J391GD6JRIY0LRVVUJ7P/boromir_shield_old_06.jpg Projects I was able to successfully turn the outside of the shield so I flipped the MDF on the lathe and started the inside. The shield had shed about 5 lbs so it was a bit easier to handle. I still worked the lathe the same way so I didn’t ruin the machine. By the time I was done the shield dropped to about 8 lbs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825666255-AQ3PGPO6HLDRMQBSOP7U/boromir_shield_old_07.jpg Projects Here is the finished inside with the plate still attached. I brushed both sides with a generous coat of shellac to seal the MDF and then removed the plate and cut out the center hole. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825666747-M1X455FPL7XQDTVYRP29/boromir_shield_old_08.jpg Projects The rim has four triangular pieces on each side. I used Aves epoxy putty to form the ones on the inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825667349-MAA3JNODJ2IQ7WFM2ZE4/boromir_shield_old_09.jpg Projects I used an Xacto knife to cut the planks into the inside of the shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825667976-XKA46A64Y3VVFM1N3UAB/boromir_shield_old_10.jpg Projects The rivets along the edge just happened to be the same size as ordinary thumb tacks! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825670809-I4QPD8J86964GFP1GOJW/boromir_shield_old_11.jpg Projects The edge rivets all in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825671731-H23ALHRYQR1JE38KTIED/boromir_shield_old_12.jpg Projects Unfortunately I found new reference that showed the planks at a different angle. I filled them with wood putty and then re-cut them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825672209-80OX8M7931KOPKQVVZX2/boromir_shield_old_13.jpg Projects I painted a base coat of black to the wood areas. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825672649-0JTOQKZKJDM34KCA4DDX/boromir_shield_old_14.jpg Projects And then, using an old tube sock, brushed in the wood grain highlights. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825673135-D16BA1Z9WWK723WA1J4S/boromir_shield_old_15.jpg Projects Since the center handle needed to be strong enough to support the weight of the shield, I used a piece of 1/8″ steel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825675260-I5QGHEIB3NGRW34OHZIN/boromir_shield_old_17.jpg Projects I cut out sections of the center ring and then cut grooves into the MDF to fit the steel. The ring sections that I cut out were saved to glue back in later. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825675742-FVMSX4LOA5F0S3V9VFXG/boromir_shield_old_18.jpg Projects I used pine scraps to form the handle. I screwed one half to the steel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825676322-ZXGUR5KNJP5R84MCQJKO/boromir_shield_old_19.jpg Projects The finished handle was painted with a glossy black and the exposed steel was painted with brass (color) enamel paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825676931-RVP9QZ2038J909MOF30G/boromir_shield_old_20.jpg Projects The handle was secured with brass screw posts that went through the entire shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825677439-GZVJNNCQC5W1W2A51XJO/boromir_shield_old_21.jpg Projects The ring sections were glued back into place and then puttied. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825677985-HHTVQYR8ANWMV1BKJBMH/boromir_shield_old_22.jpg Projects I added thumbtacks as rivets to the inner ring. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825678544-CURB41OAVZSDVG4HV262/boromir_shield_old_23.jpg Projects The outer sling hardware was made from a 3/16″ threaded rod. I removed the threads from the center with a bench grinder. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825679576-B7E511GN29MRZPEUAD8G/boromir_shield_old_25.jpg Projects The threaded ends were inserted through the shield, cut flush and then bolted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825679065-NKYGS8DECVNDZQX942LW/boromir_shield_old_24.jpg Projects The threaded ends were inserted through the shield, cut flush and then bolted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825680395-IB1CWHGRRD9LX1R3TT7O/boromir_shield_old_26.jpg Projects Each of the rim “triangles” have three brass rivets. I used brass plated nails and trimmed off the heads to use as the rivets. I drilled a shallow hole and then epoxied them in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825681054-3FQACIMMREKWS1R10BGY/boromir_shield_old_27.jpg Projects For the inner strap bracket, I bought a 35¢ galvanized steel joist hanger and pounded it flat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825681496-QR479I8GNV20HMVDE0HV/boromir_shield_old_28.jpg Projects I trimmed out the shape and bent up the end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825682134-GMJAX050QJU5AB7YJ1UQ/boromir_shield_old_29.jpg Projects The bracket was attached with three screw posts, drilled through the body of the shield. The heads were a bit big so I ground 1/32″ off the diameter. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825682991-4807P73MVC5DY6TC4FS8/boromir_shield_old_30.jpg Projects I was able to find some vinyl that exactly matched the leather used for the film shield. I cut off a square piece and then, starting at the center, glued the cover to the outside of the shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825683478-P2BPOPENSQVAT36GF90C/boromir_shield_old_31.jpg Projects The cover completely glued down. The vinyl was stretchy enough not to crease or wrinkle. After the glue had time to set, I used an xacto knife and trimmed off the excess. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825683920-8PQOW0QKQLIZVDH5MRS8/boromir_shield_old_32.jpg Projects For the outside rim triangles, I contact-cemented styrene to the vinyl and then puttied the seam to make it blend into rim. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825684501-B1XDMJSVY96YES2Z7VPO/boromir_shield_old_33.jpg Projects I glued together two 3/4″ pieces of MDF to make the boss (The metal center of the shield) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825685173-3FPKSUWP928XLS96GJLH/boromir_shield_old_34.jpg Projects I attached it to the lathe and shaped the boss. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825685532-RJB6ZQ7RRR4N2876XBY7/boromir_shield_old_35.jpg Projects I used Aves epoxy putty to carve the wings. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825685942-UXX1BOAJ2M4JSR9HSQRK/boromir_shield_old_36.jpg Projects I carved one star using the same method and then molded it in silicone. I cast copies of it in resin and then glued the pieces to the MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825686440-IM8XG8CSII242RRLY9F6/boromir_shield_old_37.jpg Projects The final primered boss. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825687152-K0KB4E1OWQULYE5BQBNQ/boromir_shield_old_38.jpg Projects Since the boss needs to be hollow, my plan was to make a mold and then make a slush cast in resin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825687694-L9G6BG94DOA3NG9G0VJO/boromir_shield_old_39.jpg Projects I slush cast a layer of resin into the mold and then a layer of resin with chopped fiberglass strands. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825688182-QBSN19URW82S00YH7S4U/boromir_shield_old_40.jpg Projects I needed to build an edge so the boss could be attached to the shield. I built up a barrier with clay and then poured resin into the edge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825689178-7X94W70BEYY5CTZMLSFN/boromir_shield_old_41.jpg Projects With the clay removed, you can see the edge lip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825689648-ZLG8TDM29C56QUXVZC0L/boromir_shield_old_42.jpg Projects The resin boss demolded. I had some dents where the mold was too thin and pulled away from the mother mold. I filled some of them with filler putty but left a few because they looked like battle damage! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825690095-OUFPZP93J656J88WE7B8/boromir_shield_old_43.jpg Projects The boss trimmed and the inside sanded, ready for painting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825690626-93T9OXMBK4ZH5A80IZZ9/boromir_shield_old_44+copy.jpg Projects The final painted boss. I started with a coat of primer and then a coat of gloss black. The silver is Testors Metallizer Stainless Steel and the brass is enamel brass (which looked too copper) with a thin coat of gold. The whole thing is weathered with a solution of india ink and rubbing alcohol. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825691608-ZW74LAMBKTKR34DE72JX/boromir_shield_old_45.jpg Projects I re-painted the rim and added the brass rivets to each outside triangle. The boss was then epoxied to the center of the shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825692122-S234XS81SM72YLCRUAYG/boromir_shield_old_46.jpg Projects The final shield. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825692455-EMMUNYONV1XM0WWLCISA/boromir_shield_old_47.jpg Projects Side view to show dimension. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532825693505-GJXJL6VXJPNTA63XHBRK/boromir_shield_old_48.jpg Projects The shield from the back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907281931-7AD9UGNHSG5K53BVNI7R/01.jpg Projects I became a re-born fan of the new Doctor Who so I was compelled to make a Tardis. I don’t have the space for a full size TARDIS so I decided to make a miniature version that would house my Doctor Who DVDs. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907281958-9RC3N0B9SEWDKCU1VN87/02.jpg Projects To keep the rough grain look, I decided to use 3/16″ Basswood. I inserted a strip of MDF for strength. The panel frames were cut out of 3/32″ strips and glued together using a MDF jig to keep them all the same. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907282558-HXFUIBUJYEEVI6C40DYS/03.jpg Projects To add the interior router edge I had to build a jig for the router guide (1/4″ MDF) to rest against. I then glued each frame to a sheet of 3/32″ basswood (with the window areas cut out). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907282659-WFWRO7FMYDRO9BAD9D8F/04.jpg Projects The routered edges on the door panels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907283159-XMK0SIH43ECM5DT3CG3C/05.jpg Projects I added some styrene for the post details. I guess I could have used basswood but I thought that plastic would offer better protection against eventual bumps. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907283268-HSX7FBQMBM4EH7PG5YJB/06.jpg Projects The panels were glued into the posts and beveled trim was added around and between the panels. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907283577-4AGU24MA46G3TT9I3FPH/07.jpg Projects The base was cut out of 1/2″ MDF with a 1/4″ MDF insert to keep the walls square. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907283791-5QTDH22YQ6N14SA6DPCT/08.jpg Projects 1/4″ MDF was used for the area over the doorway with beveled strips to frame the doors. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907284074-9THCWDPWQLE51M6Q1M5A/09.jpg Projects The Police signs were made with 1/16″ basswood. Eventually I’d like to add lighting to this model so I made the boxes removable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907284243-FGGMHCGL6T2X3M2B5087/10.jpg Projects I painted the insides black for the (eventual) backlighting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907284563-VZWZ8YH531SQ6QN4X062/11.jpg Projects I cut the roof out of 1/2″ MDF on the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907284708-024UEAWIPPXYT58HNTI0/12.jpg Projects The final touch to the roof was a bit of corner detail. The roof is still removable. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907285109-WNTDHN2GSLY4DLG4OQUL/13.jpg Projects I made the phone door out of plastic with a brass rod inserted as a hinge. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907285373-JGRDYEJPN6RTHSBP86Y9/14.jpg Projects The door inserted into the door. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907285808-MC58UJT4R6W10F1VLOLR/15.jpg Projects For door handles, I used staples. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907285899-ZDS6FUD7A87X0XPX9RD0/16.jpg Projects I used pliers, tin snips and files to shape the staples into the handles for both the phone door and main door. They were CA glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907286279-3F974Z0ANVIEUDYE5UGS/17.jpg Projects I found some tiny brass hinges to attach the doors. Unfortunately I had to hang the doors to open out because of the limited space inside once the DVD’s are inside. Oh well… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907286466-KAZLKZPRKHLCIQZVJS7C/18.jpg Projects The window frames were cut from strips of 1/16″ basswood. I made a jig out of MDF so they would all turn out the same. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907286582-QI1NYOZ241S2XLY0W53R/19.jpg Projects After much experimentation, I figured out the window glass. I used .02 clear styrene, frosted it with Krylon Matte Finish and then added clear caulk, stippled with a toothpick, for the “shower glass” panes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907286982-VHNXD2K0NYGAKRH3IAD9/20.jpg Projects For the top lamp, I needed two plastic frosted tubes to make the inner and outer lamp lens. A Bic pen and a Dial Complete pump (area around the spring) supplied the parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907287078-4HMYLEWPKGWBD8CCY9A7/21.jpg Projects The lamp top and bottom were lathed out of a dowel, with brass rods forming the posts. To make the cage around the outer lens, I masked off the panes with scotch tape and painted with primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907287331-6NCF2Y6MH8ND1LM4EKGZ/22.jpg Projects The assembled lamp. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907287547-ELNIK52J3P40OZRAUF7X/23.jpg Projects To eventually light the windows, I built a interior box out of 1/4″ MDF with tin foil reflectors. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907287692-7YE5412N4EQCXXMAS19U/24.jpg Projects The inner box was lined with black felt. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907288226-ZD2T3N45JEIY6CWHJL9P/25.jpg Projects The lock was “lathed” out of a golf tee with a power drill and a file. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907288319-Q29EBZ2DNF018TCYTTYE/26.jpg Projects I picked up a doll house lighting rig with little bulbs pre-wired to a battery pack. I put a bulb behind each window, in each police sign and in the lamp. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907288629-UIHKGY6DMQBYLEJOW567/27.jpg Projects The final TARDIS! The phone door sign is a laser print from a tight screen cap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907953730-XORU02R41F9QHRNAEI7D/balrog_old_01.jpg Projects Last year NECA Toys came out with a fantastic Balrog (from Lord Of The Rings) that I couldn’t resist. He stands 24″ tall and has a wings span of 42″! Unfortunately he is so top heavy, within a few days his legs would bend and he would fall over. The Balrog spent the next 9 months face down on the living room floor until I could devise a solution. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907954626-M15O5UQ5O9QSAWCCA113/balrog_old_02.jpg Projects I decided to make a stand with a support to take all that weight off his legs. The cool dwarvish columns holding up the ceiling of the Mines of Moria seemed like a good solution. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907955206-RD0B36YYXNQ1BO8SNDXU/balrog_old_03.jpg Projects I did my 3D prototyping in Strata3D, basing the details on the info I could get from screen captures. The column is smaller than it should be in relation to the toy but it looks better at this size. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907955573-F6XK38UY1SU46NW1IF62/balrog_old_04.jpg Projects I laminated sections of MDF together to make the sections of the column. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907955927-X3R1PKYFRQWXYSWKLOIL/balrog_old_05.jpg Projects I cut off the upper corners using the table saw. I used various thickness of basswood to make the panels on the base. The thick, darker panels on the bottom are 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907956207-N1L02R2AHVXPW7394HE1/balrog_old_06.jpg Projects The final primered base. I used the same materials and technique to flesh out the next sections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907956406-8E8UNY2W7WRH8RDCZPZI/balrog_old_07.jpg Projects The top of the column would actually ascend to the ceiling but I wanted mine to stop at Balrog waist level. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907957120-5AKVBEYSPKBAFI5E1UIA/balrog_old_08.jpg Projects The base was cut from 3/4″ MDF with steps carved with a router. The tile design was transferred to the board by placing the laser print face down, brushing lacquer thinner on the paper and then rubbing the back of the paper. The thinner softens the toner allowing it to transfer to the board. I used a carving bit in the Dremel to carve the tile seams. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907957559-KYXZB085Q8UH4GWW7KZ5/balrog_old_09.jpg Projects I then made a Silicone mold (with plaster bandage mother mold) of my wood column. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907957851-9B4I7S6SIHTK4UYTM588/balrog_old_10.jpg Projects I cut a threaded steel rod to fit inside the length of the column and attached a length of wire at the top. The wire will eventually tie around the Balrog’s waist seam and hold all the weight. A piece of plywood holds the rod in the center allowing the wire to hang outside the mold. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907957993-5N0I4BYBTO76541Y063C/balrog_old_11.jpg Projects I mixed up some concrete and poured it into the mold. The first result had some nice detail as well as some nice crumbly, damaged-looking areas. I got some cool cracks at the base and interesting pits. While the concrete was still drying, I roughed up the top to look like the top had broken off. The upper part looks deformed but it must be the angle that I shot this…it looks better in person. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907958685-KWWXYR5KVRDB0AJW4DMX/balrog_old_12.jpg Projects I secured the column to the base by putting exposed threaded rod through a hole in the base and attaching a nut. I then took Aves epoxy putty and covered the seam at the bottom and filled any cracks that I didn’t like. I then brushed on some acrylic paint to bring out the pattern. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907958816-ESPR06NVDKCK1489IMBL/balrog_old_13.jpg Projects I gave it a light sanding afterward to age the paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907959394-5I5PG39CLRQDSRCT2B0V/balrog_old_14.jpg Projects Everything got a grey overcoat to pull it all together and knock back the color. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907959643-D70A5TARDHWBQ8XOSU27/balrog_old_15.jpg Projects I applied an india ink wash to bring out details and weather the piece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907960098-QIMEXIX75ETOSW8WAF42/balrog_old_16.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907960204-D1T8ILZX78M9CT95MM6C/balrog_old_17.jpg Projects The Balrog now has a new home and SO FAR the hasn’t fallen over. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907960677-8AAGSLJKEIL2ZEH7NJ9I/balrog_old_18.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907960789-TVXUCCAPOLFZZV5C7SOL/balrog_old_19.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532907961567-Q5851LTHUO8F491G41H7/balrog_old_20.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910467487-U04NB5DVRHKKVTS30NXX/01.jpg Projects My sister is a big anime fan so I decided to make a replica of this sword from D. Gray-Man for her birthday. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910467569-AIG84LLEL2MTMDYWYQ6A/02.jpg Projects To make this sword safe for conventions and Cosplay events I decided to make the blade out of wood. I used a 3′ x 1/4″ x 3″ piece of Red Oak and cut the beveled edge on the table saw. I figured out the angle I needed and cut a slot into a piece of MDF. The wood was put into the slot and the edge could be cut perfectly on each side! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910468026-CZX83YQ8VVYQY7RP6DZP/03.jpg Projects The tip of the blade was shaped on a belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910468183-Q1HZYIL1Y937Z0C4MFY4/04.jpg Projects To remove the grain in the wood, I sealed it with shellac, primered and sanded. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910468765-U7W6TJEK9GA4D1IZYYI0/05.jpg Projects The blade was painted with a Krylon semi-gloss black. The black was then masked off to expose the edge so that it could be painted silver. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910468917-7OK4299UPLWB29V6NBUF/06.jpg Projects The hilt was constructed out of 1/4″ MDF as a box. The center channel was cut out with the table saw and cleaned up with X-acto knife and files. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910469364-RZHQDKMVNV1W2NUOY31S/07.jpg Projects The hilt was sealed with shellac. Seams and larger holes were covered over with wallboard joint compound and sanded smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910469505-HVLBAI190CQETTT00EW3/08.jpg Projects The trim was cut out of .040 strip styrene and CA glued to the MDF. I used a strip of half-round styrene for this band. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910470046-MF2H0S6XZQEVHTT6Q1CT/09.jpg Projects The scabbard was also made with 1/4″ MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910470112-4J8LM6SVJI1LSAWOGWQK/10.jpg Projects To protect the blade’s paint as it slid in and out, I lined the interior of the scabbard with a fake suede called mole-skin. It’s soft like suede but ultra thin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910470799-7OEZBJOSSD1BFUEXXZJW/12.jpg Projects Once the two halves were glued together, I rounded the edge with a router. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910471250-05G8MSCSTBYC5U6POO8X/13.jpg Projects The end was plugged with a small piece of MDF and then rounded with a router. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910471916-8QTI2HRVFCJ2GM9H5TT4/16.jpg Projects To make the opening a little nicer, I contact cemented a loop of mole skin around the opening…. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910472153-F85M18SN0PARNIGS18M8/17.jpg Projects I used two bands of .040 styrene to make the collar of the scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910472351-C5A1KQ2DDD8EGVAO3NQR/18.jpg Projects The final sword. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910472569-H8Z7U28YKMKI7GD7KVZ3/19.jpg Projects Hilt detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532910472853-JEXKT5E9FPKBP4P6HK1N/20.jpg Projects Sword in scabbard. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911607945-VOT70DV41Z2LCDXXSZUR/hellboy_old_01.jpg Projects I was a HUGE fan of Mike Mignola’s comic book “Hellboy” long before it was a movie. Even though there were official prop replicas produced, I had 8 days of unused vacation time and a pile of scrap MDF so I decided to make my own “Right Hand of Doom”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911608177-OPH282US8L8AP4JY60K6/hellboy_old_02.jpg Projects I wanted to make a wearable version of the Hand so I scaled the plans appropriately…maybe a bit bigger than the original just to accent the outrageous size. I laminated a bunch of 3/4″ MDF discs together to form the forearm, all hollowed out EXCEPT for the ends. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911608692-GZV2QG5CMTIWK8ZZWY8H/hellboy_old_03.jpg Projects After it was smoothed, I cut out the ends. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911608906-9NYC3YXGXPCEREKJI122/hellboy_old_04.jpg Projects The hand was constructed the same way, but with only a small hollow pocket for my hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911609143-AEBC7B6I2BO0DZAG1JJ0/hellboy_old_05.jpg Projects I cut a dowel (fitting inside the wrist) to give me something to hold while wearing the hand. The hand was also lathed for smoothing and shaping, then the “palm” was defined with a cut on the table saw. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911609513-JY8TN4RMGOJOIF7ZNICS/hellboy_old_06.jpg Projects The final hand was to have a closed fist (unlike the open hand of the Official prop replica) so I had to form each finger joint individually to fit in this position. Note the extra knuckle on each finger! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911609812-N9PYS8RKUXT58NBVXAQL/hellboy_old_07.jpg Projects More definition to the hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911610365-C569FN8YCPPHMKYB3XNM/hellboy_old_08.jpg Projects Here is the handle inside the wrist. The other notches are mistakes…I needed the Hellboy hand to line up with mine inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911610733-2RYDYQBVW2PSIW7AUB5W/hellboy_old_09.jpg Projects As most of the pieces were nearing completion, I needed to figure out how to replicate the ancient stone texture of the hand. On scrap of MDF , I started with a bullet-shaped grinding stone bit to rough up the surface. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911611009-OVERKWU93ODZO7XWM6GY/hellboy_old_10.jpg Projects Next I used a round grinding bit to add pits. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911611575-HVQK3CB6QYOU77IYBF1V/hellboy_old_11.jpg Projects Then I used a fine grinding stone bit to add cracks. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911611842-VE12U1LTCJL1PB4LPWYO/hellboy_old_12.jpg Projects The final step was to spray some red on it just to see how it looked! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911612098-OQVKHUOHDEBAYK7W18HN/hellboy_old_13.jpg Projects Adding texture to the fingers… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911612365-IJJ189SZDS74ZV2OHTY4/hellboy_old_14.jpg Projects Texture added to the hand. With the hand texture done, it was time to tackle the disk-shaped knuckle plates. Since the back of the hand is rounded, I had to cut holes for the disks to sit into. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911612615-TJPZFMVDB39ME14UFNSR/hellboy_old_15.jpg Projects The knuckles blended and textured. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911613038-DIFUP3TKTD7ERSEW5WUM/hellboy_old_16.jpg Projects Forearm textured over several DAYS. After texturing, I sealed the MDF with a Sanding Sealer and then applied a rust red automotive Filler Primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911613173-PBVRAVFL21PV9I96LD1P/hellboy_old_17.jpg Projects I liked to color so much, I decided to proceed to applying the wash to bring out the details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911613597-9C0J7GTVYGPE9FV9P15U/hellboy_old_18.jpg Projects I planned ahead and added a lip at the end of the forearm so I could attach the hand with wood screws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911613719-5CXIJSA8VKCZ8R4CLHKD/hellboy_old_19.jpg Projects BUT before I could do that, I needed to line the inside to make it more comfortable to wear. I found a cool burgundy leather textured vinyl that would work great. I cut a piece to size, glued the seam with contact cement. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911614058-F6IMDBKV29EYTFVYZMNV/hellboy_old_20.jpg Projects Since it’s an interior lining the seam had to be glued on the inside… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911614184-Q61UGC7DAOEMTGWPMHVI/hellboy_old_21.jpg Projects The lining inserted into the hand… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911614587-4E8OP0FEI7EMXU2ADPSM/hellboy_old_22.jpg Projects The wrist end was tacked into place with small nails. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911614738-1AJN76O8UG9EJR8BATX5/hellboy_old_23.jpg Projects From the other end, I attached the hand to the forearm using long wood screws from the inside. Then Foam padding was inserted BETWEEN the lining and the forearm walls. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911614950-AGEVVFGOFUKGV16DJIOC/hellboy_old_24.jpg Projects Then once everything was in place, I glued the edge of the lining to the forearm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911615067-9YJAOF72J7RB7L8RG4M1/hellboy_old_25.jpg Projects Anyone for a game of “Demon Proctologist” or “Alien Drug Mule”? https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911615373-J2E4FQ6XBJA8F8KJN5J3/hellboy_old_26.jpg Projects I used the same MDF method to build a sturdy base for the hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911615663-MCD5F322DZXLJF3X5PKV/hellboy_old_27.jpg Projects I wanted to make a nice logo plaque to mount on the base. I printed out the Hellboy comic logo in reverse, placed it face down on .060 styrene, wet it with lacquer thinner and burnished. When you remove the paper, a nice copy is magically applied to the plastic! I trimmed out the logo with an Xacto and glued it to heavy .090 styrene plastic. I found some cool bolts in the junk can and drilled holes in the plaque for them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911615825-5FCH7UD9PE5J3SVLMI61/hellboy_old_28.jpg Projects The plaque was painted and weathered exactly like the hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911616290-C43S8SAAICG1E93OII6L/hellboy_old_29.jpg Projects The final base. It was textured with shellac applied with a sponge and then painted black. I also added some felt bumpers to the top to protect the finish on both the base and hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1532911616405-MGOV3JXI40AAFX7TOGP2/hellboy_old_30.jpg Projects And since it’s wearable, here’s what it looks like on a human. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360812747-8RL93WZ7GJUN85IJ4Y8Y/horn_old01.jpg Projects I was commissioned to build Boromir’s Horn of Gondor. This just happens to be one of the props on the top of my build list so WIN-WIN! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360812898-SMV9GTRN1DPLVVMIIZGP/horn_old02.jpg Projects I considered using a real horn as a base but couldn’t be sure that I could get one the right size with the right curves. I decided to model the horn in 3-D to control these factors. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360813974-NQQW71Y4Q3WJASCPC95V/horn_old03.jpg Projects I pulled the file into Pepakura and exported it as a paper model that I could assemble. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360815457-8QH9CIRV8L1PNZDZ6D8L/horn_old06.jpg Projects I slush cast some Smooth-On SmoothCast 65D into the paper building up a thick shell. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360816498-CLQNI6VW97OS276ET3AM/horn_old08.jpg Projects Once the entire horn was cast, I smoothed out the folds by sanding and adding Bondo. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360816728-PKW2VI7QKQNJCYF9LKLB/horn_old09.jpg Projects The completed horn. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360817384-G6VKAZLNHDEZE0B29STO/horn_old10.jpg Projects I lathed the mouthpiece from a block of basswood. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360819302-CRY1ZI03QNRO8D50JI0X/horn_old15.jpg Projects After a few false starts, I got the decoration drawn out correctly and started to apply styrene piece to the mouthpiece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360819739-LRWXX49MFZ59MLZZFD2F/horn_old16.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360820113-LDX4UMHBLRBI0ZPS9JOG/horn_old17.jpg Projects I lathed the mid band from another piece of basswood, carving in the raised strips on either end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360822736-FN4TQRP5W8X37XGYBHSP/horn_old19.jpg Projects Since this band has a repeated pattern, I decided to cast a portion of the band and apply the decoration to it. This completed section would be molded and multiple resin copies would then be applied to the full basswood master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360825343-MCFI83J2XRLDBXSLSA25/horn_old21.jpg Projects To show you the size of styrene pieces I had to carve, here’s a small piece of detail. I was cutting these under a magnifying glass. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360829911-GQDIJGZY8X6H9J8QFLBA/horn_old22.jpg Projects The final mid band pattern underway! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360830505-HDECBLDHO91X79N9MZU3/horn_old23.jpg Projects I made a mold of this pattern piece (the pink one) and a silicone positive (the white one) of the band section. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360847200-8H2FKCR9Z7ECXSN9ESK3/horn_old24.jpg Projects I would mix up a small amount of resin, drop it in the pink mold and then press in the positive white mold, squeezing out any excess. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360848506-WT6LKIMM1K533DX4DYDI/horn_old25.jpg Projects The result (with varying degrees of success) was a copy of just the detail parts that can be glued onto the band master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360850589-3DJ63MVFJ822B5PAD1LB/horn_old26.jpg Projects The completed mid band master. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360851040-M3OI9QWQODF02MDE8Y8P/horn_old27.jpg Projects The end band was too big for basswood so I glued a bunch of MDF together and shaped it on the lathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360851398-B7V9GPCZ5FAHXOQUNXNI/horn_old28.jpg Projects After shaping, I sealed the MDF with shellac, applied coats of primer and sanded it smooth. I was able to achieve a glass smooth finish by buffing it with a paper towel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360853255-P7XD0P363K0PHSG0RRGF/horn_old32.jpg Projects I used the same strategy to detail the end band, applying styrene to a cast resin section of the band. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360854144-K2OPN0SSKXCEBOUNAIHZ/horn_old34.jpg Projects After casting copies of the detail, I started gluing them to the end band. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360855310-6GDMZVGKFSVJVZZ9NSRP/horn_old35.jpg Projects Time to show off some of the fine detail on this piece. What a pain! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360864231-IZ6768LQJDVKIIJ5SM2C/horn_old44.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360870498-IHOZUXGFRSL9T7K2GU77/horn_old49.jpg Projects To make the strap loops, I cut a dowel and heat formed thick styrene over it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360877230-HOQ9AOLPPBGU0OOIJG15/horn_old51.jpg Projects The final finished horn! I got to enjoy it for a few days before… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360878478-002J484J9S0PCXEK07WA/horn_old52.jpg Projects …I had to cut it in half for molding! I did not enjoy doing this. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360880605-X4VEK55EHP4O1LMGJUAY/horn_old54.jpg Projects To make sure the two halves went back together correctly, I glued a PVC ring to one side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360884637-JCLFNIY8NXGSVWX9VR6W/horn_old55.jpg Projects I Dremeled out the other side so the PVC ring would fit inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360884841-DAIUEA0PX7JA9CJT7UHV/horn_old56.jpg Projects I glued on a piece of half round styrene to act as a registration key. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360886372-XH1LZHY3Q4HRUEK2PHQU/horn_old57.jpg Projects It slides into a slot on the other side so that the parts will always line up correctly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360889163-CMZ9QU6JKHCAAMPNP2FZ/horn_old61.jpg Projects I made two-part molds of both of these parts so I can slush cast hollow copies https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360902277-BM18UYHH26PYETP8XAMS/horn_old65.jpg Projects A test fit of the cast copy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360904263-JUT4NLHSRJL93BJFGU8B/horn_old67.jpg Projects I sprayed a base coat of white for the horn sections and then dry brushed acrylic (“Buttermilk”) to add some texture. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360904777-4NY3XCRI4TTOER6DVUJ4/horn_old68.jpg Projects I dry brushed the tip of the horn with a flat black acrylic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360906574-Y5XR0UM08YR2WNCM2X58/horn_old70.jpg Projects The metal parts were painted with metallic gold and silver and given a wash of black to bring out the detail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360906712-4YPU9EC6MB25VWXZC4F5/horn_old71.jpg Projects Finally, I masked off the metal and sprayed a gloss coat over the horn parts. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360916392-UTYHXRUHZ286SR4KHLLP/horn_old77.jpg Projects To make the strap I bought some black leather Latigo lace. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360917045-187G7969NM0SPUDSK777/horn_old78.jpg Projects I used a round braid (I found instructions online) to weave the strap. After a few attempts I finally got it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360919976-ZO3OCRPXOWZMJXID2XJR/horn_old81.jpg Projects To complete the strap, I attached them to the rings and back braided (the lace goes back through the loops) the lace to tie it off. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533360921562-ETNAEPXR942VEQNHBWQ5/horn_old84.jpg Projects The completed horn! I drilled out the mouthpiece so it will make noise. I guess I don’t have the lip for it as all I could get out of it sounded like a constipated bugle. I guess that might confuse the Uruk-Hai long enough to run away! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533429073131-DR63N5HHIJA9OT54WLOT/poochie_old01.jpg Projects The name’s Poochie D, And I rock the telly. I’m half Joe Camel, And a third Fonzarelli. I’m the kung fu hippie, From gangsta city. I’m a rappin’ surfer, You the fool I pity! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533429073225-33F1E7IENU2QK8NGGKGM/poochie_old02.jpg Projects A glaring omission from the World of Springfield toy line was Poochie the Dog from the episode “The Itchy & Scratchy & Poochie Show”. I took as many screen caps as I could from the episode and made my plans to scale with the Itchy and Scratchy figures. I roughed out the figure with Sculpey on a wire armature. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533429074100-RBQL3CZ5GXUISO411NA1/poochie_old03.jpg Projects I used Aves epoxy putty to add details. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533429074100-O186J5QT33S7J1UET34P/poochie_old04.jpg Projects The surf board was cut out of .09 sheet styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533429074584-S1MIAJ6MHSERFA0ZOKRQ/poochie_old05.jpg Projects The final painted figure. The glasses are .02 styrene, the base is MDF, the fanny pack is a small piece of MDF and the zipper tabs are tiny pieces of styrene. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533429074727-QPUHBX50BDFG61D6S58W/poochie_old06.jpg Projects The base was made to match the existing Itchy and Scratchy figures. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511277078-91SHUKGDO82VBMLTFV7Y/abe_old01.jpg Projects The episode features a great flashback showing a young Abe Simpson fighting the Germans in the closing days of WWII. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511277191-8YBI4PXO1UO7G0747NX6/abe_old02.jpg Projects I bought a used “Raging Willie” as he is one of the few Simpsons characters in shape and had a cool action pose. I made a rough mold of Homer’s brother Herb’s head and cast a new head. I also referenced the Ranier Wolfcastle as McBain for the Simpsons-style of sculpting the military uniform and equipment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511277822-RP2JGXK0F79MYDVV5FBC/abe_old03.jpg Projects I soaked the Willie figure in boiling water for a few minutes and then popped off his head. I used white tape to mask off the seams and used Aves epoxy putty to start building the new uniform pieces. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511278481-T5W4SAWNRJAHNLBBIQ00/abe_old05.jpg Projects I added epoxy putty to the casting of Herb to build Grandpa’s features and haircut. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511278969-Y167DJL13MV3UK1ESLLB/abe_old06.jpg Projects The painted head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511279782-1TCKTE9JVOZGTXX97VU7/abe_old09.jpg Projects Later in the episode Abe is wearing a backpack. I cut a piece of MDF to shape for the main section and side pockets. The straps were cut from .02 styrene (after MUCH prototyping). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511280879-Z53HJYRBK1G8JYWY2U0N/abe_old10.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511281158-P7CXDSMJ3WOATVATAPUT/abe_old11.jpg Projects The grenade was formed from Aves with a nail stuck in it. When it was dry, I stuck the nail in a drill and lathed in the horizontal grooves. I attached small styrene blocks for the upper part of the grenade. The grenade ring was made from round styrene bar stock. I heated the plastic and wound it around a brass tube. I snipped off one link and then glued it closed. The “handle” of the grenade was made from a sliver of aluminum. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511568736-EI4NZWFMHAIW9C2TFEJQ/abe_old07.jpg Projects The belt pouches were made from thick styrene with thin plastic folded over for the flaps, I put a dot of CA glue on the flap for a subtle button. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511281832-WPZ6T4EPN4V5ETIS9BKP/abe_old12.jpg Projects I made another cast of the head for making a helmet that would fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511281927-8UGEPM5GTHQKUX7BSOR1/abe_old13.jpg Projects I covered the form with Saran Wrap and used Aves putty to sculpt the helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511282397-WUJVFKFAX1EL7FB73NI1/abe_old15.jpg Projects Afterward I used the dremel to thin up the interior lip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511284398-DEPSE2W09YY8SYM6RX25/abe_old20.jpg Projects The sniper rifle from the episode was nearly identical to one that came with the figure of one of Fat Tony’s mobsters. I merely repainted it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511282730-UJG8LWBE24WOF5FHBJI3/abe_old16.jpg Projects Abe also used a Thompson Submachine gun and I couldn’t resist building it. I used laminated styrene for the parts and a brass tube for the barrel. The muzzle was formed by putting Aves on the end of the tube and then putting the tube in the drill and shaping it with files. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511282808-S1LGEAN11VT3S622LOFC/abe_old17.jpg Projects The Thompson painted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511283188-J5RVNAS55VUXRXC428CB/abe_old18.jpg Projects Here is Abe Simpson all assembled and painted. I also added his sergeant’s stripes on his helmet and the Hellfish tattoo on his right bicep using laser decals. I did my best to replicate the details of the episode, fighting my urge to make the details accurate to real life. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533511283597-AMYYLXSARIWIFP64BRB2/abe_old19.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512608828-FO5FIQZ0MR92KHVXO2ZT/hitler_old01.jpg Projects Since all “World Of Springfield” playsets have spots for three action figures. The natural third banana should be Abe’s sniper target, The Fuhrer himself. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512608956-410WDL91OBE6PLFYUXRN/hitler_old02.jpg Projects For a base figure, I started with a character called “Sarcastic Man”. I soaked the figure in boiling water to soften the joints and then popped off the head. I molded a rough head out of Aves epoxy putty on a screw and once that dried, carved in the basic features. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512613362-CMSWUIO6OBTLGZ3N35O7/hitler_old03.jpg Projects I continued to refine the facial features, form cuffs, collar and the lower part of the jacket. Some more refining of the features, added putty glove cuffs, collar tabs and tie and then used strips of styrene to make the epaulettes and shoulder belt. Added the collar over the shoulder belt with Aves putty. The putty is extremely strong even in paper thin applications! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512613575-2ROQ3BK3LAMRODLYVYS4/hitler_old04.jpg Projects More Aves putty to make the hat. More styrene to make the belt and the band across the visor of the hat. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512614062-K875Z8D5K5N273R79LZ3/hitler_old05.jpg Projects The final painted hat. Added are a styrene eagle and gold tabs at the ends of the band. The button on the ends of the band were made with a dot of CA glue. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512614399-52262OGJH0JC1187CUXM/hitler_old06.jpg Projects The final painted figure in all his rat-faced glory! The swastika armband is a laser decal. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512143102-5PZPDKUAIIXT7BHSTFEE/monty_old01.jpg Projects As I finished the Abe Simpson, I thought it would be cool to do some of the other characters from the episode and maybe even a playset to display them on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512143195-TJ1IIMWZDKFD0UW6GBHQ/monty_old02.jpg Projects Burns started with the basic figure with the hair, waist and trouser cuffs Dremeled off. Using the Aves epoxy putty, I started building the collar, hair and fatigue pants. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512143706-0L7TXAGMKQQWTBOXMO65/monty_old03.jpg Projects The next putty layer consisted of pockets and the sweater draped over his shoulders. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512144068-ZY9F7UD3LU3LWRIPC05C/monty_old04.jpg Projects And then finally the sweater sleeves hanging down the front. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512144613-YQSFFA7VDWIQBICYBGW5/monty_old05.jpg Projects In the episode Burns spoils Abe Simpson’s shot at Hitler with a stray tennis ball. I cut small sections of wire and held the vertical and horizontal sections together with masking tape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512144785-0FRFC398HPG56852DG0G/monty_old06.jpg Projects I crossed the two sections and then added a drop of CA glue at the intersections. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512145191-W2T1K8HRXNSBA180V2NB/monty_old07.jpg Projects After that dried, the wires were cut to fit the styrene frame. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533512145284-N2792Z1ZFM1EBJ10VWYG/monty_old08.jpg Projects The final painted figure. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513263307-RR2E7YCY5XECOTO5J1ML/ardennes_old01.jpg Projects For the playset for my WWII Simpsons figures, I chose the snow covered ruins featured in the flashback. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513263375-R90E1O5J8EZK6W6RH2NB/ardennes_old02.jpg Projects I cut the base and walls from 1/2″ MDF to match the dimensions of the other World of Springfield line. The broken bricks were roughed in using the Dremel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513263832-70UQ0FNOF9HJMOQOO79J/ardennes_old03.jpg Projects I scribed in the brick pattern using the Dremel with the router attachment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513263903-P7DOOU640QCUBQPQF7HT/ardennes_old04.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513264229-8VLKRCNQX25J3E7APYFN/ardennes_old05.jpg Projects The snow on the walls was formed by applying Aves epoxy putty over plastic wrap (so it won’t stick to the MDF) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513264338-854T6DK409Z50UWX040S/ardennes_old06.jpg Projects The snow on the ground was made with a coat of Sculpey. I placed the three figures on the sculpey to mark the positions of the foot holes. Once baked, I Dremeled out the foot holes so that they would look like they were standing in thick snow. And so they wouldn’t fall over all the time! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513264769-YEI77P6U8YMIKOD36IXS/ardennes_old07.jpg Projects The final painted set with the figures in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513679058-MV62DAZJK7LCR9U2SBBJ/Kunai00.jpg Projects I was commissioned to make a replica of this traditional Japanese weapon….only HUGE! The client wanted it 4 feet long for cosplay. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513718883-KCGPAS29K2AI1VNC0ZLB/Kunai24.jpg Projects I constructed a 3D model of it in Strata and then imported it into Pepakura for conversion into a building pattern. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513680628-R1XL3S5FATKVTUCN2BR7/Kunai02.jpg Projects I printed out the pattern, cut the knife sides out of .09 styrene and then glued in ribs to support the form. I cut a hole through the ribs for a 1″ dowel that will run through the entire prop. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513682504-ZLS0LTEIGQQHEY3TWORV/Kunai05.jpg Projects The spaces between the ribs were filled with an expanding foam. The tip has been sanded flat in preparation for skinning. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513680746-M2RB3YGOW5M5OA0RO4DR/Kunai03.jpg Projects The final panel was glued in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513681830-GJJYBMA40FCX91ISJSMV/Kunai04.jpg Projects I used a 2″ PVC pipe for the handle. I inserted MDF spacers to support the wooden dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513682992-2A5O8FLFOLBWERIKY172/Kunai06.jpg Projects The handle slides onto the dowel and is glued into place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513685798-O4NA29KXMT7P0PQJVKZS/Kunai08.jpg Projects The end ring was made from layers of MDF to form a hollow box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513687955-Q5WK1440A5NNOWGSC0ON/Kunai09.jpg Projects The box glued together except for the top so I can work out the handle join. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513690541-TSUOK7WUDLCMHOFH2CFQ/Kunai10.jpg Projects I rounded the box edges with a 1/2″ router bit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513690948-UND0RHP043JZ9IYPNR5T/Kunai11.jpg Projects The box glued together with the handle opening cut out. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513693635-XMDMRE9AZPBAI8NSDEZ5/Kunai14.jpg Projects The four sides of the back of the blade were glued into place and filled with foam. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513696056-BMZAW6FZ15CCQBAS8JIU/Kunai15.jpg Projects The final blade painted with primer. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513696790-7DZHG0ED6SIT7NLG64W6/Kunai16.jpg Projects The interior was filled with expanding foam and the MDF was sealed with shellac. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513702313-U2P3709C2BU55RY47UOR/Kunai17.jpg Projects The ring glued on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513703946-YUTRPT22CU3OPXNH6D7M/Kunai19.jpg Projects The painted knife. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513705619-894O83JQ0ZA9JX7P1MZD/Kunai21.jpg Projects I dyed 1/4″ cotton rope red (per client’s request) and drilled a hole in the handle for the start of the wrap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1533513718885-MX7WC3AS1JWAO74P6ZTP/Kunai23.jpg Projects The final piece! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109365366-IZAPXBE9GF65048ZO5YL/01.jpg Projects This gun was built for a contest run every year by the Blaster Builder’s Club. The rules state that you must create a blaster of your own design using a toy gun as a base. I started with a partial M-16 that I had sitting in my scrap plastic box for 20 years. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109368398-FCQ4K4YD4EZ34RQ374QY/02.jpg Projects Measuring this, I started designing my blaster, first in Illustrator to work out the basic look… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109369634-8CHJPJ8O5R50CPPK27SR/03.jpg Projects …and then in Strata3D to fine tune the design and work out all the dimensions. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109370449-MMQBJVT2O4G6OQNP8B0C/04.jpg Projects The stock, handle/sight and half of the magazine were hack sawed off the toy to make room for the new parts. A plug of MDF was glued into the magazine well for rigidity and to guide the new magazine. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109370737-K5RRLAIVENVDRYFWJYDT/05.jpg Projects For the new stock I glued two pieces of scrap 3/47″ MDF together and shaped it with a jigsaw and Dremel. The barrel is a length of PVC pipe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109372078-URB5PV1QFBOSS0H6M0HK/07.jpg Projects The new magazine well was made from MDF as well as the “plate” that will eventually hold the muzzle shroud. All were attached using the threaded rod (test fitted here). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109372962-2H3BZLOUJJ72311EZ4MI/08.jpg Projects The magazine was also built out of MDF. The channels were cut using the table saw. The screws secured the base to the magazine but were left exposed (for looks). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109373057-7ZFVCLO19FOLC0P71T79/09.jpg Projects The magazine fit like a glove, needing no mechanism to hold it in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109373394-Q0BCDPPUNXNT6HLOMBGV/10.jpg Projects A test fitting of the progress. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109373566-LYGP76I2MTNGUKXN82B4/11.jpg Projects The butt plate started as a simple MDF box and was shaped on the belt sander to smooth all the edges. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109374034-75CWWKORVCWVSMY3CARW/12.jpg Projects The faux barrel was made by shaving a sliver off a 1-1/2″ PVC pipe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109374140-NLBZYIAQX05OENW2VSXX/13.jpg Projects The receiver cover started as a simple MDF box, with notches and supports allowing it to fit over the toy gun. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109374507-FZOJTW6HBGOZJUVMG4FY/14.jpg Projects I wanted to preserve some of the nice detail on the side of the receiver. The M-16 has some cool looking switches. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109374647-QJUJV8I4ODDCGQ33TRBP/15.jpg Projects I used scrap styrene to build new geometry on the sides while still taking advantage of the details I like. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109375064-ITY8W87FM44POI5ZDZT8/16.jpg Projects Looking through my greeblie box I ran across an I.V. valve from when my cat was sick. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109375293-JTDGBZ0QF26C30ZCWDIP/17.jpg Projects I split it in half and applied them to both sides. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109375668-FB4GYRRF696T5BVW54IK/18.jpg Projects IV lock on the left side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109375829-P1Z033P87OOIZ9SMCMNV/19.jpg Projects The cheek guard was a bit tricky as it had to wrap over the flat top of the stock as well as the round tubing of the barrel extensions. I glued together 3 pieces of MDF with appropriate notches. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109376282-8SEZ0UT65XAUGNO7MGA2/20.jpg Projects Rounding the edges with the belt sander… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109376404-F5PQ3P3S418UYFIWD1WJ/21.jpg Projects …cut away excess…. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109376841-C9S17N9AXGT0GQI9RA3F/22.jpg Projects …and it slides on from the end. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109376962-2N2DL2NPK4MOEA4X0BJM/23.jpg Projects The front of the scope was formed by melting a scrap of styrene around an oval piece of MDF. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109377324-YN7FBHDQ1XW7C50IB03L/24.jpg Projects The pieces for the scope: 1″ PVC to attach the front lens, Lathed wood for the body of the scope and a piece of 2″ PVC for a last minute addition to the eyepiece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109377439-CANOL8N6VKBY87W45EBZ/25.jpg Projects To fake a lens, I grabbed some sunglasses from an eye exam and trimmed out the rear lens. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109377788-0D7JCD56ES4QKTE3XDOJ/26.jpg Projects I painted the rear scope body and added a screw knob I found in the “screw can”. The assembled rear scope. The “lens” is held in place by the PVC eyepiece. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109378011-QHAVY03QUTXZZYD1M6YO/27.jpg Projects The barrel shroud was vacuformed over MDF masters. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109378379-3A2Y7FVUB0GM99WC0SYH/28.jpg Projects They were trimmed and glued together with a thin strip of styrene along the seam for strength. The shroud was then screwed to the plate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109379774-VBTOK8HGA82R5V8BKYXF/29.jpg Projects After I painted the magazine, I decided to re-address the issue of a transparent window. But as I was in the final weekend before the deadline, I “cheated” and just printed them on a sticker! I needed a way to keep it in so a spot of Velcro did the job. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109379994-K7IQ935VC41MJDZ151SM/30.jpg Projects The final scope attached to the rifle with exposed hex screws. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109380229-ZGLZLCS7QVJC0FKKSVM0/31.jpg Projects The final submitted photo https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534109380820-4CF53YVF98RPQRCUOLZO/32.jpg Projects This year’s competition was extremely tough but I managed to tie for first place. In a tie breaker vote, I won the top spot! This was a fun and educational project to work on. I spent about 24-30 hours constructing it and only had to spend $16 on paint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110564604-Q6CVV08KTZ6RTCTTR4FM/stormbreaker_old01.jpg Projects This hammer was designed By Walt Simonson in his brilliant run on the Thor comic book in the late 80s. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110564613-WWDIL1KG190BT2MYBB9Q/stormbreaker_old02.jpg Projects For the handle I used a 18″ long 1.5″(measured by inner dimension) PVC pipe with end cap. The end cap was cut to a height of 1.375″ and a .25″ bevel was sanded on the edge with the belt sander. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110565021-AYS7PQAQ5NXN72YNP3C7/stormbreaker_old03.jpg Projects I cut out all the profiles from 3/4″ MDF. Half the head profiles have a 1.75″ hole drilled into them for the handle. Two disks of MDF were glued together and then sanded down to a thickness of 1″. I sanded a 15º bevel to the side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110565472-SJZXQ3ZU9CWLHUGNPTSN/stormbreaker_old04.jpg Projects The head profiles were glued together and the sanded smooth. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110565520-WNUEQ66ISGKF72KB3KHO/stormbreaker_old05.jpg Projects I sanded the axe edge on the one end and continued sanding to round the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110568848-SQ6VG8HOD7DAI6VOFLJX/stormbreaker_old06.jpg Projects I cut a 5.25″ disk with a 15º bevel and screwed it to the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110569778-ZE4DKCFB31KV4IJV91E1/stormbreaker_old07.jpg Projects I applied Bondo to smooth out the surface and cover the seams. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110570667-VKNEZVACG1ZP93HI6WX5/stormbreaker_old08.jpg Projects Stormbreaker has 3 rings at the point where the handle meets the head. I cut 2.5″ disks from MDF and then cut 1.75″ holes in them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110573139-S2W3CKPXRU3ZCRFL6HV9/stormbreaker_old09.jpg Projects The rings were all rounded on the sander. Here they are on the handle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110573483-W0Z0LSOPWSWX1RM8MN41/stormbreaker_old10.jpg Projects The spike on top was sanded from a 1.5″ wooden dowel. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110573527-CS6TSTXIFGJOY8JKDYZS/stormbreaker_old11.jpg Projects The spike was cut off to length of 2″ to fit into a hole routered into the top. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110573969-5WT786RZKW2RM9V8M30D/stormbreaker_old12.jpg Projects After MANY coats of automotive primer, I painted all the parts with Rustoleum Gold paint. Unfortunately the metallic gold is very prone to scuffing so I coated it with Dupli-color automotive Clear Coat. It dulled the finish a bit but not too badly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110574012-OSQ03NWMT7NRN4A1X9OT/stormbreaker_old13.jpg Projects The strap was made with the same method as Mjolnir….two strips of vinyl contact cemented back to back to form a loop. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110574469-OA1RWQUZ2MFBRWQ0FRGM/stormbreaker_old14.jpg Projects Here you can see the lamination and the extra overlap that I included at the spot where it gets attached to the hammer. I stained the vinyl with acrylic Burnt Sienna and black washes to get a more realistic leather. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110574522-XLKJ3DDFO0JHN7UQF6NJ/stormbreaker_old15.jpg Projects A .625″ dowel was screwed onto the cap (before it was glued on) and the the strap was epoxied to the dowel. I painted an upholstery tack with the same gold paint and attached it to the inside. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534110574990-EV2HAZ6JXPM1QRRBMOVC/stormbreaker_old16.jpg Projects The final hammer. The handle of Stormbreaker is surprisingly short in comparison to Mjolnir. It seems that there’s just enough room for Bill to get both his giant space-monster hands on the handle! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111206955-ENPCTD27SAJHAU08VNXD/mammoth_old01.jpg Projects I got this kit back in 1972 and assembled it as only a child of 7 could…badly. Somehow it survived my childhood and multiple moves to eventually return to my hands when my parents retired. I don’t know how accurate it is but I thought it was a nice sculpt so I decided to rebuild it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111207056-UQQ80MR47DAAXAL0VAWK/mammoth_old02.jpg Projects First I disassembled the kit and gave the whole model a coat of primer. I reassembled the legs and puttied the seams while re-scribing the hair as best I could. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111207510-OU4SO590T58YBRVSVGIC/mammoth_old03.jpg Projects My original intention was to merely clean up seams, paint and then build the kit as designed. Once I put the legs on, however, the hips seams are quite pronounced and looked too “toylike” I puttied up the seams and then put it aside to dry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111207643-3GTZS2Q7OX2F4E905CNL/mammoth_old04.jpg Projects Hours later, I was able to carve the hair into the putty seam and it matched pretty good. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111208112-L0GSSY9V7ADK7QE4VPUT/mammoth_old05.jpg Projects Even with the seam covered, it still looked like a toy. I researched elephant muculature and built additional mass to the hips and shoulders. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111208704-12A1CO0N49H0QKFS45RM/mammoth_old07.jpg Projects The head on the original kit was built to pivot on a ball joint for a limited range of movement. This created a massive gap in the neck area that I would need to fill. I chose to turn the head slightly to the left and tilt it. The seam was filled with epoxy putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111208826-1P3OVYWS17NZEA7JRJJ9/mammoth_old08.jpg Projects For realism I added little dangling clumps of hair from the bottom of the neck, hanging off the belly and from the tail. To disguise a pronounced belly seam I added a row of hanging fur down the belly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111209292-ZLN2OMEM66QRV7YBTTI7/mammoth_old10.jpg Projects Naturally a snap-together kit would not address an animal’s genitals. Seeing as the mammoth looks male (to me), if I didn’t do something about it it would look strange. I based the penis sheath on modern elephants (You don’t want to see what’s inside…think “Dune”) and according to a REAL frozen mammoth find, the testicles were internal…probably a good idea during the Ice Age https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111209623-L1E6GX0QSQXMQMHO68KR/mammoth_old11.jpg Projects During research, I read that mammoths only had 4 toes whereas modern elephants have five. Naturally the kit had five. In the end, it was a good thing as I could make the toes protrude a bit and add bits of hair hanging over and between them. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111209863-QCHXVZPTFB0922BDEW2I/mammoth_old12.jpg Projects The mammoth was ready for painting. I painted the tusks with a basecoat of ivory paint (duh) and the rest of the beast with semigloss acrylic black. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111210710-TWP64CPGWQKVWSFT0AMW/mammoth_old14.jpg Projects So the mammoth would seem to be standing firmly on the rock, I coated the soles with epoxy putty and pressed it into the cliff (covered with Saran Wrap). After the putty dried I painted them with black washes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111210362-JK4GZ8BMNBG9SCMUP9MK/mammoth_old13.jpg Projects I added model railroad gravel to the base of the cliff and little bits in crevasses. I watered down Elmers glue and sprayed it over the gravel to lock it in place. I added some railroad grass (very fine green threads that you cut to size) to the base as well as a dead tree that I recently discovered in a box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111211243-IUTD39N4A58B4Z0LAQ16/mammoth_old15.jpg Projects I based the painting of the mouth and trunk opening (?) on those of modern elephants, making them a pale greyish pink. The tusks were weathered with multiple washes and the eyes were painted to match a modern elephants (strange, I know). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111211367-09YKXWU3NHNJ0D6XEZSD/mammoth_old16.jpg Projects Here is the final kit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111211730-NE6XGFJ4PBQJIYFQPCI5/mammoth_old17.jpg Projects The rest of the fur was drybrushed on with various shades of brown, leaving the underside black. The toenails were painted with a light grey and weathered with various dark washes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111833581-DFHXVH5R81CH6YW6DVQ1/wooden_old01.jpg Projects The Tick, a large, blue, strong but stupid and INSANE superhero, is upset that his sidekick Arthur wants to skip “Craft Night”. Sulking in his apartment, the Tick sees “a little boy trapped in a block of wood” and decides to free him. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111833685-JCDB9RJJVC3VQH34LFIK/wooden_old02.jpg Projects After makings some measurements based on screen caps from the show, I cut the parts from a pine 2×4. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111834224-WOYGL68O7TJQYNYHPPBP/wooden_old03.jpg Projects The arms were cut from pine, using staples and eye screws to attach them to the body. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111834318-MVCQCFC3DAYXBQMT2ULC/wooden_old04.jpg Projects The gouge was the hardest detail to reproduce as I had to interpret a drawing into 3 dimensions. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111834694-1QA5GRJGAF1YZN5ASOTT/wooden_old05.jpg Projects The face was painted on using red and black enamel paints. The “buttons” in the animation were hollow outlines which I interpreted as drill holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111834839-KI9J0YWTFL04BYEVB8PJ/wooden_old06.jpg Projects The arms are attached to the body with a staple and eye hook. The legs are attached with wood screws. The hole in the leg is significantly bigger than the screw to allow some side-to-side movement (presumably for martial arts moves). True to the Tick’s craftsmanship, the legs are mounted asymmetrically. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534111835148-M1T53M2UNXD7G2UU9S90/wooden_old07.jpg Projects Little Wooden Boy guards the city with an unwavering gaze! Beware naughty spawn! Little Wooden Boy is on the job! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113202758-QHJGC3UHDYRV43Y27DUD/01.jpg Projects I finally decided to build this kit after it had been sitting in my closet since 1993. At first glance, the detail looked great but as I started to research the “real” armor I noticed some problems. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113202877-SBCM6PB2TG7DBP8QY6DW/02.jpg Projects All the pieces had really soft edges and inaccurate details. Some pieces could be brought up to “spec” with just some adjustment others would have to be trimmed away and rebuilt. Worst of all, the blaster was entirely the wrong size, a crappy casting and inaccurate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113203335-0VIMY1ODSSIAX69GE543/03.jpg Projects At the waist, I had to reshape the crotch and butt plate and decided to remove the blocks that hang from the belt as they were molded in place and should hang free. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113203424-KPT3PG40OWLJHN4D97EJ/04.jpg Projects I used an Xacto knife to sharpen edges, re-shape armor plates and cut under the armor where appropriate. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113203902-YUFGGC21FQZGA07Q52PW/05.jpg Projects The helmet was a big mess! Besides the general cleanup and edge refining that I did on all the other parts, there were some problems with proportion and shape that would have to be fixed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113204015-27ASV3JHFDXHGOSTPPN6/06.jpg Projects I cut off the “ears”, extended and reshaped the “snout” with putty, removed the front grill and “microphone” tips, cut out spaces in the “teeth” and lined the inside of the helmet with epoxy putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113204416-B1ARLVB0HKXQJS565XNS/07.jpg Projects I had to completely reshape the eye holes with epoxy putty. I pushed Sculpey through the eye holes from the inside and sanded the lenses round. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113204486-MPDGSCSOT8KDHBDV6K0I/08.jpg Projects The inside of the helmet was painted black and the trim was made from a thick plastic coated cord from the craft store. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113204921-Z1WEXNU346YP5TY2HUHL/09.jpg Projects The BIGGEST problem with this kit is the torso barely has a neck and there is no way to attach the helmet without gluing it directly on the shoulders. So the helmet would sit correctly, I decided to sculpt a head for it. And if I was going to go to the trouble of sculpting a head, I’d use my own! I used Sculpey for the head and epoxy putty for a neck seal to hold it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113205008-RMLKAPRI8KLAIU9GJTRG/10.jpg Projects I constructed a base from styrene to simulate the decking on the Death Star. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113205462-I4NW0YW77NXCQXH1GXF5/11.jpg Projects The Blaster looked OK at first glance but it’s way too big, the casting is bad and the sights and folding stock are CARDBOARD. I downloaded the ENH version E11 templates from the Blaster Builders Club and used these reduced to 27% to build a new one from scratch. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113206782-06GPYUHBEHIDAOHTX3OT/12.jpg Projects I cut a new barrel from 3/8″ brass tubing and the grip, magazine and Hengstler counter were made from laminated styrene. The receiver spring was made from copper wire wrapped around 1/4″ aluminum tubing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113206996-BT148C66RZ6D073P28M1/13.jpg Projects Pictured here is the completed magazine with styrene details. The front and rear sights were made from pieces of brass as were the folding stock and trigger guard. I removed the pistol grip that was molded into the Trooper’s right hand so the new one could slide in. Unfortunately I couldn’t attach the trigger or trigger guard until it was put in the Trooper’s hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113209428-A5WR8TWZ1802J2NXS8H1/14.jpg Projects Here is the completed body of the gun. It has a 1/8″ brass barrel, the muzzle is laminated styrene and the bolt handle is a VERY tiny nail. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113210125-6CWNQWAPU7MA5AQO8LW9/15.jpg Projects I made the “scallops” out of 1/4″ aluminum tubing, Dremeled to fit and super-glued in place. Here is the barrel with magazine, front and rear sights, end cap and scope rail attached. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113210842-NGO1EX7OAETXE0TY20W8/16.jpg Projects The scope was made from aluminum and brass tubing, a wooden dowel and the blue cone-shaped “clicker” from an ink pen. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113211275-NGFD6T76L66EDY6XRU7A/17.jpg Projects The t-tracks covering the barrel vent holes were made from styrene t-bars. All I had to do was cut them to length and taper the ends to make it look as if they were inserted into the holes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113211386-H3WF12S1N9S6URL9X3L5/18.jpg Projects I stripped out a few wires from a 9-volt connector, wound them around a tube and super-glued them in place. This was by far the HARDEST part of the entire project. Those damn wires really didn’t want to cooperate! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113211774-EWE02YRV6WRJH578958G/19.jpg Projects The final gun compared to the original kit’s version. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113211878-08N4JN3X1NSS8GHNQWUP/20.jpg Projects Here is the final assembled gun. I also used a little silver paint to simulate wear. I kept it pretty minimal as I figure a Stormtrooper with a cushy assignment like the Death Star probably has pretty new gear and probably doesn’t see a lot of action (Besides smugglers and Wookiees running loose…) https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113212538-563G9QXL98O4FFWNQ45M/21.jpg Projects The final kit, with and without helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113742436-FACSVNQFB2FRNEQ1VO7I/mjolnir_old01.jpg Projects I am a huge fan of Walt Simonson’s work as writer/artist on Marvel Comics THOR in the late 1980s. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113742525-9TIQ05P05KTRBT3MBXQF/mjolnir_old02.jpg Projects I cut sheets of 3/4″ MDF to laminate into a 9″ x 4″ x 6″ hammer head. I drilled holes through the centers of all sheets. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113743092-XY4W3G2O9FFX1V3UK8GA/mjolnir_old03.jpg Projects The bevels of the hammer were cut by tilting the table saw blade 45 degrees. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113743320-AC0C477UK0UYOJR93RA0/mjolnir_old04.jpg Projects The porous edges of the MDF were coated in Bondo spot filler and sanded smooth. I then gave it several coats of automotive sandable primer. The “cap” was cut from a piece of plywood and given a bevel. The whole thing was sprayed with more primer coats and then finally a Krylon Aluminum. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113744084-MRZGC9OKXFZKY5NTCKK4/mjolnir_old05.jpg Projects For the handle, I decided to use an old tree stake that I had sitting around. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113744197-O3F1L3I24A64PCZON2NI/mjolnir_old06.jpg Projects I wasn’t confident using leather but found a tan vinyl that I could cut myself. The grip was wrapped with four 60″ straps in a tight overlapping pattern. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113744596-PQO85FQX2MLM9JH82UV6/mjolnir_old07.jpg Projects The pommel was covered with a circular piece of vinyl, glued over the edges and then wrapped with more vinyl strapping. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113744695-F58IRZN9YNMO66A9KJFH/mjolnir_old08.jpg Projects The straps looked a bit flat and vinyl-y so I gave the wrapping an acrylic wash of darker browns to weather it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113745041-MQAPT3J2O0QNVKCR9LLF/mjolnir_old09.jpg Projects The loop was formed by laminating the vinyl back-to-back. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113745149-OLHIP1XF577LSNAVLOIA/mjolnir_old10.jpg Projects The loop was attached with a wood screw with a plastic snap-top cover. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534113745551-FP0EZFWFGC9Q41NDUY6C/mjolnir_old11.jpg Projects The hammer is purposely huge, nearly 24″ long (not counting the loop), and quite heavy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550003441-IDC6CFKC3WKW43BUQLN4/halo_old_01.jpg Projects I decided to build the Halo armor for Halloween of 2005. The helmet, as you’ll see, was scratch built. Remember, this was years before Pepakura, foam smithing and 3D printing. I think the helmet turned out pretty good. The armor, well, not worth showing. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550003538-O0ATNT3XG4CBAFP4RUTM/halo_old_02.jpg Projects I started with a basic batting helmet. I found one that was a bit small on my enormous melon so that when the final helmet is complete I wouldn’t look like a bobble-head. I tore out all the padding so I could add it later once I saw how the final helmet fit. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550004067-3QOWDHEJL4J01Y0CMZDK/halo_old_03.jpg Projects I cut off the visor (brim?) and a bit off the side to get the basic shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550004200-AH68O5SRYN1911FDBPSV/halo_old_04.jpg Projects I screwed on a strip of steel for the jaw portion of the helmet https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550004822-YD95MYQLXKIQ6I4O8LNC/halo_old_05.jpg Projects To work out the basic shapes and how they fit on the helmet, I got a pack of poster board and worked out my templates (I only did half). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550007686-72D0NBV6HOKL9BOYWF0B/halo_old_06.jpg Projects Using sheet styrene I assembled the lower jaw. I made a track just below the top for the steel strip to fit into. The visor and cap sections were built much the same way…kind of a hull structure (.080) that I would skin with thinner plastic (.040). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550008284-0Q6WC9FSCH8SZBF74YES/halo_old_07.jpg Projects Unfortunately, I am not that precise with my cutting so I rely heavily on putty to cover my mistakes! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550008420-2GL2FX3ECGBYABFH03E1/halo_old_08.jpg Projects The back under construction. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550008946-6W25BMRPUX9XZGGIJFVP/halo_old_09.jpg Projects I used a 2-part epoxy foam to fill all the structural parts. Now the helmet is solid and heavy! Bring on the Covenant bastards! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550009704-HY2AN77ZBTW3130EB58W/halo_old_10.jpg Projects Here it is assembled with a thin support rail for the visor. I also inserted some rubber hose for the respirator. I plan to add cooling fans behind these. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550010072-ZWFGOHCITNWC0RY9USYY/halo_old_11.jpg Projects It was pointed out to me by someone on The RPF, the brim on the helmet was too short. Adjusting it wasn’t that hard as I just built a frame around the old one. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550010198-052VVR9VOAV20K2RVTAL/halo_old_12.jpg Projects While I rebuilt the brim, I cut some posterboard to plan out the visor. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550010617-TUV5T8GP4XN14RXDQ9UO/halo_old_13.jpg Projects Some styrene detail to be added under the brim. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550010792-UTGPV1M5QXIVUMU9905M/halo_old_14.jpg Projects I cut the visor out of .08 Lexan, glued it in place and put gold mirror tinting behind it. The “real” Halo faceplate has an embossed pattern on it so I cut the pattern out of styrene and (tack) glued it over the Lexan. I used a “chrome” metallic gold paint that has the same color but a differnet level of reflectiveness. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550011234-8YL9XZRG7YF8I5LHQBUH/halo_old_15.jpg Projects After one night at Halloween, I discovered the helmet got hot FAST. The faceplate also fogged up. I added two computer fans powered by a 9-volt battery. I finished out the interior with fun foam to cover some of the less attractive construction and cable tubing to hide the wires. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550011323-MS3IW095OIBUKAC5F178/halo_old_16.jpg Projects The final painted helmet. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550011652-LVCH7LUMC7VUDPTE8N9J/halo_old_17.jpg Projects Amazingly enough, the opaque pattern on the visor doesn’t restrict my field of vision at all! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534550011824-P891WDYT3PP4OI313EXR/halo_old_18.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115737538-SR0KYU63EXIJG41YJWQK/sandman_old_01.jpg Projects This gun is from the 1976 sci-fi film “Logan’s Run”. I was able to find some very detailed plans online, including WORKING acetylene blasting models (as in the film)! I used plans from the original prop maker, Richard Coyle. It’s rare when you can find any sort of detailed specs, so this was a joy to work on. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115738054-JGTA5Q9XKAO9OUACQDIY/sandman_old_02.jpg Projects First, I cut out the grip halves and trigger according to the plans. I used .08 sheet styrene laminated to build the right thickness. The muzzle was cut out of PVC and beveled on the end by attaching it to a drill, turning it into a makeshift lathe. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115738485-97EO6EL3L7DM9PAN8YYX/sandman_old_03.jpg Projects I wanted to be able to pull the trigger so I took a spring from a crappy ball point pen and inserted it under the trigger (deviating from specs). https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115739008-FIRQKT3RIVMZHGX1TCO3/sandman_old_04.jpg Projects The receiver tube and gas canister are stock PVC parts cut to size. There is a small barrel hidden within the muzzle shroud…for that I used the barrel of an old dried up marker. The knob at the end of the gas canister is laminated styrene. The stage came together pretty fast, so I don’t have photos of the assembly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115739475-I3REHBYE3ZL325WP3FMF/sandman_old_05.jpg Projects I then airbrushed the interior of the muzzle. For final painting with spray paint, I didn’t want to miss or overpaint any of these confined areas. The receiver tube was epoxied to the grip and puttied to hide the seam. I cut out the grip plates from sheet styrene and sanded them to shape. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115739970-LY8JNYPPDVG42TGYNBI8/sandman_old_06.jpg Projects I masked off the trigger and the interior of the muzzle and gave all the parts 5 coats of primer, sanding where needed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115740402-1577P2CCEI2BLZ0OGI5U/sandman_old_07.jpg Projects I made the ignition plug (below the muzzle) according to the plans but it just looked like a spark plug. Since mine didn’t have to work, I scrapped the part and rebuilt it using a plastic wall anchor and a metal dowel. It is the same size as the original part, retains the spirit of the original but looks more futuristic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115740791-O1X5QUC1U9OXSLPCEXFP/sandman_old_08.jpg Projects Same situation on the arming switch in front of the trigger. The original plans call for a toggle switch. I adapted a bolt for a decorative substitution. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534115741335-6GUDWXXGPE1HYONB0T00/sandman_old_09.jpg Projects The final paint for the grip plates was Krylon gloss black (many coats). The rest of the gun was painted with semi-gloss black (Also many coats). Krylon suggests that spray paint be given 5 to 7 days to cure, so I waited to epoxy on the grips. The grip plates look strange only coming up halfway, but I was surprised how comfortable they were when assembled! Very solid hold and an ambidextrous thumb rest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116074987-56V4X7UYWHF7O9QTHLYK/mace_old01.jpg Projects This mace started as a quickie prop for my Sauron Halloween costume. The shaft is a cedar closet dowel, cut hexagonally with a hacksaw. The head piece and butt were pine discs of various diameters on a threaded rod. To get it done in time, I cut flat styrene blades and glued them to the head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116075625-8IO56XRO3BMUCS8KNN7I/mace_old02.jpg Projects After the holidays, I decided (or was compelled by dark forces) to bring the mace up to spec. The blades were re-cut out of 3 sheets of 3 mm plastic laminated together. I used the Dremel sander to grind the bevels on the blades and modeling putty was used to build the raised dividing fins. The new blades were glued to the head with 2-part epoxy. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116076175-AK7FDH46IZD1D69W5G55/mace_old03.jpg Projects The grip ribs and spiked band (halfway up the shaft) are styrene. The hand guard was made with a pine disk and wood putty. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116076615-L7LYAI6JU2S52J9DB8EO/mace_old04.jpg Projects I added the “Black Tongue” runes to alternating facets of the shaft with craft “puffy paint”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116235445-WKHUCM84XB9LRPIJ7BH3/mace_old07.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116531782-HZ6CBZMWP3B7C2YW55OV/E11-1.jpg Projects This replica of the “Return of the Jedi”-era Imperial Stormtrooper Blaster is entirely handmade from PVC pipe (all tubular elements) and styrene plastic, the exception is a resin pistol grip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116536149-RD9830A9N0TVDKLTL3Q8/E11-3.jpg Projects I started building before I realized there was a difference in the weapons used in the original trilogy. My barrel cutouts are from “A New Hope”-era while the rest is ROTJ. Oops. Perhaps a model variant between the eras? https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116535038-76PSW9SOCZO5FTMIY8XG/E11-4.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116542360-TT4WF2SGS8YH108KG2PB/E11-6.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116543692-I9BKMUGDG6AZH0AHXUS0/E11-7.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116544915-CS3F5B0GZOX2CBQ2DBUK/E11-8.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116545571-BTXB373WK6ZE3RY5TCF6/E11-9.jpg Projects The Stock extends and locks just like the real one. I even put in a small spring in the butt plate so that it snaps back in place when folded up. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116550480-ZZFNKSWGZZP22N97P9CD/E11-10.jpg Projects The prop has a working trigger and safety, which took some figuring out as the “forward” position is “FIRE” and the “vertical” position is “SAFE”. The trigger has a small spring pushing it forward and the safety employs a double lever that blocks the trigger when on SAFE. The pistol grip itself is a resin copy from a REAL Sterling, I bought from a guy at the Blaster Builders Club. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1534116551189-4ETBY5TYK1D35C0OBFHA/E11-11.jpg Projects The barrel is PVC pipe. The sling ring, front site and heat vents were all formed by using a heat gun and bending 3mm styrene plastic into shape. It takes some practice (and burns) but you can achieve some unique shapes. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896877982-7R1OQNDFNXRV17ZRSZK5/Carl-0001.jpg Projects As a collector of action figures, I knew I had to make Carl. I could make the plastic parts but the uniform would be a different issue. More on that later. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896956100-7IKYEPT0MSEKX1TMLZF7/Carl-0084.jpg Projects The special features of the Bluray had nice detailed images of Carl so I could draw up plans for the build. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896983205-41WAQU4U07CNMLXHC2T6/Carl-0098.jpg Projects I bought a 12” soldier to see how they made the joints. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896998582-ROP4P4YCXVMXG78G9TNE/Carl-0103.jpg Projects The sample toy utilized a joint pin that allows the limb to rotate and pivot. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896893349-O0RQO09VQJYQ9DZ0UWU3/Carl-0015.jpg Projects Now that I had a plan of attack, I pulled my plans into Strata 3D to use as a template for sculpting. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896896286-VYLII3HQWIDHLM2NEBB1/Carl-0017.jpg Projects I sculpted one side of Carl’s head and “mirrored” the geometry. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896916204-W8OF6630COOC4BYODK29/Carl-0039.jpg Projects All the main body parts sculpted. Once finalized, I flipped the geometry for the other side. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896931961-2WDCIDF1BSQVQ6PT4GN7/Carl-0054.jpg Projects The joints (as learned from the sample toy) are discs for the joint to bend and post that allows the limb to pivot. I planned to print the pins at Shapeways for added strength, so I added a collar that would be cast in the same color as the rest of Carl’s skin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896936491-QZPLDREW3AXGUTG9F3T4/Carl-0060.jpg Projects The wrist also needed semi-spheres to help cover the joint hardware. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896922036-NA3WAZEUSV45CFLJJ563/Carl-0044.jpg Projects Arm with joint hardware inserted. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896924426-KW4OKLYVMUR4CHHXXIG0/Carl-0045.jpg Projects I experimented with giving Carl more realistic torso muscles, but since Carl is an 80’s toy, I went with the stylized G.I. Joe musculature. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896959226-6SDCQYT4W1MM54JMHGDY/Carl-0085.jpg Projects - Masters for each part back from Shapeways. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896963678-6IF6DUTM38UV9YDV5G2D/Carl-0088.jpg Projects Masters for all Carl’s equipment. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896967869-PHGA4A2NL1IPRLCOFRC1/Carl-0090.jpg Projects Test assembly of one arm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896971716-R9K8CSDPZ5EQW0QKF7NT/Carl-0091.jpg Projects Test assembly for one leg. There is a space above the boot for the pants leg to “tuck in”. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896971919-VCMX8LCIA4HX85BXVH6A/Carl-0092.jpg Projects Showing the range of motion. The boot will also rotate on the shin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896975414-ACA6IRG3255HLZEHRIXT/Carl-0093.jpg Projects Test fit of the head, torso and pelvis. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896974961-RKAOUA3ICLHWKPT8AL77/Carl-0094.jpg Projects The elbow joint has a small protuberance that prevents the arm from hyperextending. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896978597-Q43CE1VKZCXB6FC3ICQI/Carl-0095.jpg Projects Range of motion test for the arm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896978601-3YZMO07YURYUZEZHZ0AF/Carl-0096.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896985082-OBPLC6NJNSFDXJY992QK/Carl-0099.jpg Projects After molding the masters, I cast up a bunch of Carl parts. I had 5 initial Carl clients. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896988641-FKVTEDM6U6SRQELZ3E9E/Carl-0101.jpg Projects I used a Dremel bit to carve out a space for the shin joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581896998909-0K8DF9PKQ5IJCT62KHSZ/Carl-0102.jpg Projects Test fit of the boot. I curved in the base of the shin so that the pants would look tucked in. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897002893-ZPM6N6W1H4E1VRV7RQ03/Carl-0104.jpg Projects A big flaw with my plans was that it was extremely difficult to get the joint tabs to cast properly. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897006840-0XRJG8O4S4PEVYY252OA/Carl-0106.jpg Projects This led me to change the joint pin that Shapeways would print to include the tabs. I would drill out a hole in each side of the cast part. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897012343-PUXDM0H6GL3K81VAL2PA/Carl-0108.jpg Projects New pin in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897016660-VH0Q3STF0GSQMWOIBX34/Carl-0111.jpg Projects New pins with resin collars. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897020637-PRJO3FBQZV24E79HSHUC/Carl-0112.jpg Projects Hip pins in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897027061-SMHFRVDWUISQMWFYH0CV/Carl-0115.jpg Projects Wrist joint pin with corresponding cover domes. Not sure why I replaced the pin with a metal one… https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897030687-DG5GUVRRPO4XH0IG2O6A/Carl-0116.jpg Projects Assembled arm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897030904-Q9Y20MAGNXPMLLWC6UN2/Carl-0117.jpg Projects Both arms in place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897035886-9XBBAH31PGFJSUFK6ZCC/Carl-0119.jpg Projects All parts in place so the last step is to seal the chest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897037555-18THMHW4QQJZXMSDJZXX/Carl-0120.jpg Projects Combat Carl, Karl, Carlos, Carton and C-Dawg. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897038550-J3XHHVDZZZPE4B7I3F1Y/Carl-0121.jpg Projects Detail shot of a painted head. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897040384-GXLZWZ849QBF12G6BQM9/Carl-0122.jpg Projects I added elastic straps to all the knife sheaths. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897042054-FBOVKWK1GRS6V6UPDCI9/Carl-0123.jpg Projects Painted shotgun shells. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897055519-BXNHFU2L8GG3IODEDPJE/Carl-0126.jpg Projects While I was working on the plastic bits, I hired a tailor to make his uniform. I cannot sew. At least nothing this complicated. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897059830-857F47PEX1789C9808AO/Carl-0127.jpg Projects Prototype Camo pants finally arrived!. I was able to locate the EXACT pattern that Carl uses and had fabric printed. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897059520-F5HQHS474PITRIY5XO7J/Carl-0128.jpg Projects Test fit of the pants. They look sharp! https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897075384-FT49GCNT3RFKMGER7ZSX/Carl-0135.jpg Projects Initially, I was going to use a gunbelt from existing 12” military figures. That plan fell apart when I found that supplies were hard to source. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897091478-6F7D5TIQTSGJ1983ODFY/Carl-0146.jpg Projects I made a functional belt buckle and used olive drab ribbon for the best. Stitch lines were drawn on with a fine ink pen. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897066085-I5CVR5XOEAKOTSLFFL9I/Carl-0131.jpg Projects Prototype vest came next. I liked the duck cloth for its weight and texture but the trim was a problem. It looks like vinyl in the renders but vinyl (on the left) proved too thick and wouldn’t take the sharp corners. Another thought was ribbon (right) but it wouldn’t wrap. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897068731-W3Q7RWG1V4YNLJANGLZA/Carl-0132.jpg Projects Back of the vest with marks for back pad and velcro strip. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897077427-0XJ0CVG8ZF7TUSCR0LI3/Carl-0137.jpg Projects After 3D printing a figure that used elastic straps, I found that it had terrific range of motion. Maybe that was something I could bring to Carl. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897078941-01AQFUOFXW6LXPHO3Z4W/Carl-0138.jpg Projects As a test, I drilled out and strung a Carl with elastic. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897082066-4UE2BBIS6BRNQCVAL12T/Carl-0140.jpg Projects With tight elastic, the figure can still stand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897083965-1SLTJ7XCC36CL2Z8V48Q/Carl-0141.jpg Projects Range of motion is much better even though the joints pop out of place. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897085477-P16RGQ54DJYWSYE3WFO4/Carl-0142.jpg Projects Arms would tie in the middle. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897085520-1ITZVZRUOLEPARWGYJ9V/Carl-0143.jpg Projects I eventually decided to compromise and remodel the joints to use elastic at the shoulders and hips since those were the areas with least mobility. Knees, elbows and wrists would have modified joint hardware to make it easier to build. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897088406-JO2LO5XGVSU9QSJF2N68/Carl-0144.jpg Projects I also found better reference of the sheath and remodeled it. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897090100-S4ODQDZHDVKE1WSWT58L/Carl-0145.jpg Projects I also made the grenades more accurate and added a flat side for easier glueing to the vest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897093232-FMIQ0RYNTJ2W488A7A7V/Carl-0147.jpg Projects New reference also showed a seam through the center of the boots and stitching on the panels. So I remade them too. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897096772-PU0GRNDX3DFJK0WNG66F/Carl-0149.jpg Projects Instead of individual buckles, I made them part of the back pad. Ribbons sewed to the vest would loop through them and glued. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897072273-MQJ5D594J2V8P7BXUAGW/Carl-0134.jpg Projects I solved the vest trim issue by sculpting the trim and stitching, printing and molding it in Smooth-On Kytoflex 30 Urethane rubber. This was glued to the edge of the vest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583350325179-MEWHZ83R2OD4UR1L5CVR/Carl-0163.jpg Projects For the hip and shoulder joints, a knotted end of elastic was interred in a slot. Once the arms (and hips) were in place, the other end of the elastic was tied tightly in the chest. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583350326732-KE4X5W2IEFWJGT5W1B1C/Carl-0166.jpg Projects Elbow pin and disk. The collar pieces on the right slide into a recess at the bottom of the bicep. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583350328604-1865V5L8W074SGBBXGQP/Carl-0169.jpg Projects Completed elbow joint slid halfway into the upper arm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1581897101519-AEIDZQANS7IRW4AM0LBV/Carl-0151.jpg Projects With kits in mind, I remodeled many of the joints. The wrist is now an insert that accepts the wrist pin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583350325349-RG9UBUFEU088ZKG86K6O/Carl-0164.jpg Projects The wrist pin is contained by two hemispheres, which is then glued into the cavity of the hand. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583350328939-YSO38JMBKSGKYU8LJW5Y/Carl-0170.jpg Projects Completed wrist joint. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583350329751-1LVNL8S8AZPYMS6WIHCV/Carl-0171.jpg Projects Wrist pin is contained in a two-part collar and slides into the forearm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583350331076-9LZNQVK19LCQ3IYSBE2O/Carl-0172.jpg Projects The client requested a removable hand like in Toy Story of Terror so I carved off most of the the pin head so it would slide into the forearm. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583474857456-PEA9T4FL16SRT0SD1OXY/Carl-0179.jpg Projects Finish Carl https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583474859285-PJXTC8FGY7U89A49XFXP/Carl-0180.jpg Projects https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583474847236-YZ1CJRF0UEKYX8UABF7Y/Carl-0174.jpg Projects While the clothing was being worked on, I had some downtime so I decided to use my day job skills and design a package as a surprise to my VERY patient clients. I printed the design on vinyl and applied it to Bristol board. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583474847691-8JYOL6BSI91M5GWSGYD5/Carl-0175.jpg Projects I used double-sided tape to add clear plastic to the window and added an insert to clean up the inside of the box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583474852114-PUP14HNA70R91SGZPV01/Carl-0176.jpg Projects Carl in his box/coffin. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583474852531-WNB49O4YYRGSAOAAILLL/Carl-0177.jpg Projects Back of the box. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1583474857017-HB4ZCQVY1093VBRG38CW/Carl-0178.jpg Projects I mocked up a vintage Toys R Us price tag as well. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522564734135-NRA50BTAFGV442FXNKF6/BPRD_icon.jpg Projects 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When you're building, you can take measurements right off your plans. https://images.squarespace-cdn.com/content/v1/5ac07765e2ccd12ae702706e/1522736577033-GL6LVGA7JAU1PC0ZF5J2/Screen+Shot+2018-04-02+at+11.22.31+PM.png Resources Apply to the clear 9 oz. cups from Wal-Mart, place the bottom line of the gauge at the base indent and pour equal amounts in each cup. For example, if you want to mix 60g of resin, pour each cup to the 60 mark (it's actually 30 g per cup but to avoid any math, I listed the total). https://www.blindsquirrelprops.com/build-list daily 0.75 2018-04-06 https://www.blindsquirrelprops.com/contact daily 0.75 2018-04-07