Archive for the 'Painting' Category

Armor Work, Painting

Progress Report 6/10/08

I was able to get a few hours in on the TK armor on Sunday afternoon at least until I got sick of being soggy from the humidity. YUCK!

I sanded down the two halves of the 02 tank and painted it with another coat of gray. This will be the last coat regardless and will move onto trimming the halves and assembling the tube.

I was also able to assemble the two halves of the bicep armor with little difficulty, although I did have to attempt to reshape the inner halves of the biceps as they are misshaped and don’t line up to the outer half well.

To fix that, i brought down my hair dryer to heat up the piece to reshape it. Let me tell you, this method sucks. Its time consuming and generally just doesn’t seem to work, even after spending five minutes warming up the area.

On the left bicep, I was able to heat it up and let the glue hold the warped area in place, but the right one, I had to warm it up, Velcro it together and then hold it in the clamp. This hasn’t worked too well so far but I’ve found that leaving the pieces clamped for a few days is helping fix the warped area.

I also tried my hand at the first shin piece and had a catastrophic failure with gluing. I was unable to keep the middle part of seam to glue together even with holding by hand. Luckily I was able to tear the two halves apart with very minimal damage. I am now going to have to work on sanding off as much of the glue residue as possible and retry.

I have seen some good talk about computer hard drive magnets being used to hold the middle together where it can’t be clamped. Thankfully, I have several old computers at work, waiting to be recycled so I pulled the hard drives apart yesterday and will try again.

Armor Work, Painting

Neckseal Came!

Yup you read it right. It came from the UK in about four days. WAY quicker than the resin Hasbro mod kit did.

Did a test fit, it fits loose but you’d never know it from looking at it. The lining is the same satin material as the bib and its comfortable. My only two gripes are that the bib is really just too long and that straps on the bib would be better replaced with elastic and Velcro. Also the satin inside the neck is a little loose like theres too much fabric and likes to poke out the top of the neckseal. Its not too bad though and it can always been tucked back in.

I forgot my camera at work last night so I’ll have to get pictures tonight so you can see the finished product.

Also I pulled the masking off my helmet last night. The paint job on the inside came out well but the outside needs to be cleaned up. It has newspaper ink smudges all over, but that should clean up rather easily.

I hope.

Armor Work, Painting

Day 4 Rundown

Received my rubber t-tracks for replacing the rails on the Hasbro blaster on Friday! YAY! These will need to be shortened to fit the shorter Hasbro barrel but they are accurate to the screen used blaster. That will happen later when I get ready to finish the blaster.

So onto the armor work. Started with doing the bracers. I followed pretty to the letter the directions from the bracer tutorial from Dave’s Garage. The two parts to that can be found here:

Part One
Part Two

Basically, I started by sanding the areas that would either have Velcro attached or glued. This takes the “shine” off the ABS plastic and makes the glue attach better.

Next, I attached the soft side of the Velcro to the outer piece of the armor. First off, you ALWAYS want the soft side pointed towards you (and your undersuit) as the plastic side will tear it up. Also doing this part first is best because having the two sides of Velcro done first can make gluing more difficult and it is easier to attach the piece of Velcro here now because its easier to access than after gluing.

After doing that, I taped the heck out of the Velcro side of the bracer to support the bracer for gluing. Then I clamped the two ends of the glue side to mesh the two sides together and then ran a piece of tape flush across the edge of the seam to mask any glue that might squeeze out once the bracer is glued and clamped.

Once that was done, I pulled out the Plastic Weld, squeezed out some into the plastic bubble from the package and mixed it quickly using a wooden dowel. Set the timer for 4 minutes and went to work and applied the plastic welder with the wooden dowel and the aligned the top edge and clamped while holding the center together with my hands for a few minutes for extra support.

Once the timer went off, I took the clamps off and removed the masking tape piece and cleaned up and excess glue with my Xacto knife.

Once that was done, I trimmed off a piece of the plastic side of the Velcro and attached it and then Velcroed the two sides together.

Repeated for the other bracer.

After that, I spray painted the insides of the bucket parts after double checking the masking tape to make sure that no gaps appeared in the masking. I used the satin black Krylon I bought for the blaster to spraypaint.

I stopped there because I started to get a lot of dandelions “cotton” seeds blowing into the garage that I didn’t want stuck in the paint.

Next up, I will probably continue onto the biceps and then move onto the leg armor. Also the gray parts are in need of another sanding and coat of paint as well as the the 02 tank still needs to be trimmed up to fit the end caps.

Armor Work, Painting

Day 4 Bracers And Painting The Bucket

Armor Work, Painting, Setup

Day 3 Rundown (Yeah its late.)

Haven’t had time to update the site with the work I did on Thursday, so here it is.

Decided to do a test fit of the bucket to see how everything fits. Got everything together and I have two issues. One, the edges of the front and back need to be trimmed for a better fit. You can see in the pictures where the edges don’t fit properly and will need to be cleaned up. And two, the ear pieces have HUGE gaps where they cover the seams on the tubes. I’m researching how I want to deal with fixing that.

Next, I masked the outside of the bucket pieces. You can see in the pictures how I did that using masking tape and newspaper. Very easy. You can also see that I cut out the eyes in the masking and then taped down the eyes. This is done to seal the eyes to keep overspray from getting into the masking and onto the face of the mask.

Armor Work, Painting, Photo Gallery, Setup

Day 3 Test Fitting The Bucket And Masking

Armor Work, Painting

Day 2 (Back on track)

Ugh. Running late on this update thanks to too much time spent trying to get my old Flickr plugin to work with the two new galleries I made last weekend. As you can see everything is fixed. FINALLY.

So Saturday morning I made it out to the store to buy the last of the tools I need for building the shell of the costume. A note to remember is that this does not include anything regarding putting together the support structure (webbing, etc) since I have not yet decided entirely what route I intend to take.

Unfortunately, as I was wrapping up my shopping, I was informed by my roommate that we’re having a cook out that night so any work I wanted to get done on Saturday got thrown out the window.

Woke up late Sunday morning, got dressed and set up my PS2 on the TV in the garage for watching DVDs while I work (SNL season 2!) and went to work.

I started out with taking the tool photos you see in the gallery below, and cut up the wooden dowel I bought for use applying the plastic welder. Let me tell you, trying to take pictures while you work is a bitch. Don’t expect much more in the way of action shots in the future unless its something I don’t have to worry about screwing up.

So after taking the tool pictures, I did some test fits. Let me tell you, wearing shorts when you do this is very helpful in getting a more accurate fit. The thighs are going to be tricky, especially since I would really like to avoid the “cannon thighs” (these are oversized and more tube-like thighs) that is prevalent in the FX armor kits.

So from there I went to test fit the 02 tank. Guess what? One side is apparently longer than the other and both sides are too long to fit together anyways. I did a little grinding down of the difference in sizes but the whole thing is going to need to be measured out and cut probably on both sides.

After monkeying with it for a while I put that to the side so I could try to do some research to see if I can find more information on better ways to do this later. So I started painting. Starting with painting the chin piece satin black, the two halves of the 02 tank primer, then dark gray, and the ear screw covers primer and then dark gray. The reason why the dark gray pieces got primered first is because I the satin black is a plastic paint, while the dark gray is not. The primer is to make sure the pieces are properly set up. All pieces also got a light sanding and about three coats.

After this I decided to grab the aerators and put them together. I am going to use the stock aerators temporarily until sometime after I finish the set and I will buy a set of screen accurate hovi mic tips to replace them and hopefully place speakers in them.

These are extremely simple to put together. All you do is take the main front piece apart, take the rubber stoppers out of them, pull out the restrictor disc with the small hole in it and place the screw through that. Take the screw on back part and remove the rubber stopper from that, and screw that onto the front piece. Do your best to keep that screw & restrictor plate straight and as centered as possible. One I had no problem with and the other I had to hold up while I screwed the back on. Once the back is screwed on it will hold the screws in place and you place the washer and nut on the screw and attach the aerator stickers. Done and done.

Next i decided to pull out the drill bits for the Dremel. Anything that will be riveted, and the helmet screw holes got drilled at 1/8″ drill bit and the ab button holes got drilled at 5/32″ (I need to double check that size though). I bought a Dremel drill bit set for the 1/8″ but if you get the variable chuck add on for the Dremel you can use most normal, smaller drill bits with it. Just remember when drilling plastic keep it on a lower setting so you’re not melting the plastic as you go. Depending on the part I was using between 2-5 speed. Also if you’re buying a Dremel for this project make sure its a variable speed model and not one of the cheaper one speed only ones. Its a huge help and again it will keep you from melting the plastic as you work.

At this point it was getting cold with the garage open and dark so I gave up for the night to go upstairs and upload the pictures I took and started my fight with Flickr and the plugin I was using for this blog.

Armor Work, Painting, Photo Gallery, Setup

Day 2 Photos