Make – Props and Costume Armor
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Loading...Make – Props and Costume Armor
Create Realistic Science Fiction and Fantasy Weapons, Armor
Shawn Thorsson
CONTENTS
- Preface
- Acknowledgements
- PART I: Prototypes and One-Offs
- Chapter 1: Building with Sheets and Tubes
- Starting Off Simple
- Battle Axe for the Wolf Warrior
- Hunter’s Rifle
- Chapter 2: Working with Pepakura
- Pepakura Boot Camp
- Putting Pepakura to Work
- Making It Hard
- Making It Smooth
- Detailing
- Chapter 3: EVA Foam
- Sourcing: Where to Get Foam
- The Basics: Making Foam Obey Your Every Whim
- Patterning
- Final Detailing
- Prepping for Paint
- Paint!
- Chapter 4: 3D Printing and CNC Carving
- PART II: Molding and Casting1. Chapter 5: Mold-Making Basics
- The Simplest Molds Ever
- Mold-Making Material
- Mold-Making Terminology
- Chapter 6: One-Piece Molds
- Easy Version: A Part with a Flat Backside
- Slightly Harder Version: A Piece with Details on All Sides
- Chapter 7: Multi-Piece Molds
- Starting Simple: A Two-Part Mold with a Mold Box
- Not So Simple: A Three-Piece Silicone Rubber Jacket Mold with a Mother Mold
- A Few Tips and Tricks for Better Castings
- Chapter 8: Molds for Rotocasting
- Prepare the Prototype
- Prepare the Work Space
- Building Up the Rubber Jacket
- Building the Mother Mold
- Rotocasting
- Trimming and Prepping the Cast Part for Painting
- PART III: Vacuum Forming
- Chapter 9: Vacforming Basics
- Terminology
- Designing the Forming Bucks
- Building the Forming Bucks
- Choosing Plastics for Vacforming
- The Simplest Possible Vacforming Setup2. Chapter 10: Build Your Own Vacuum Forming Machine
- Begin by Building the Clamping Frame
- Heat Sources
- Common Configurations
- Building the Platen
- Vacuum Sources
- Putting It to Work
- PART IV: Painting and Weathering
- Chapter 11: Basecoats and Masking
- More Than You Ever Wanted to Know About Paint
- Basecoats: Building a Believable Finish Starts with a Solid Foundation
- Masking and Stenciling
- Chapter 12: Faux Finishes
- Metal
- Leather
- Wood Grain
- Carbon Fiber
- Chapter 13: Weathering
- Additive Weathering
- Subtractive Weathering
- Mud
- Rust
- The Path to Patina
- Scorches and Burn Marks
- Burnt Metal
- Blood Spatter7. PART V: Bringing It All Together
- Chapter 14: Strapping and Padding
- Padding
- Armor Attachment Options
- Strapping Materials
- Buckles and Related Hardware
- How to Attach Straps to Stuff
- Design Considerations for Strapping Your Armor Together
- The Tricky Bits
- Odds and Ends: A Few More Strapping Tips
- Chapter 15: Showing Off
- Handlers
- Field Repair Kit
- Posing for Photos
- Planned Photoshoots
- Index
INDEX
Numbers
3D model. See also Hunter helmet
choosing and designing, 36
of cube with notch, 30
entering dimensions, 36
printing, 30
rearranging seams, 36
sizing, 31
template, 31
3D printing. Seealso Pepakura Designer shareware; printing
build lines, 84
versus CNC (computer numeric control), 82
A
ABS (acrylonitrile butadiene styrene), choosing for vacforming, 163
ABS pipe, for battle axe, 17
acrylic
choosing for vacforming, 163
paint, 194
additive weathering, 222–226
adhesives
for battle axe, 11
for binding sawdust, 5cyanoacrylate, 43
for Pepakura, 34
aluminum foil
using duct tape with, 74
using with armor, 70
ankles, wrists, and necks, 254–256
armor
after making forming platen, 172
attachment options, 247–249
back of hand area, 72–73
breastplate, 73–74, 77
cup shape, 75–76
dents and scratches, 77–78
elbow area, 73
gauntlet, 70
painting, 80
paper template, 75
prepping for paint, 79–80
raised and layered details, 78
rivets and screw heads, 79
seams and panel lines, 77
set of parts for, 174
tin foil, 70
tools and materials, 58, 70
trimming gauntlet, 78B
baking tray, using for clamping frame, 165, 169–170
bandage shears, using for forearm, 71
bar clamps, using for battle axe, 10
basecoats. See also paint
clothing choices, 198–199
ergonomics, 197–198
overspray protection, 197
portability of small objects, 198
primer, 199–200
spray can handles, 198
surface preparation, 196
wearing respirators, 198
work-space preparation, 197–199
battle axe
ABS pipe for, 17
cutting shape of, 13
driving screw, 12
dry-fitting parts of, 14
finishing, 18
glue, 11
handle, 17
holding together styrene layers, 15
MDF (medium-density fiberboard), 8PVC pipe fittings, 17
shaping blade, 8–9
shimming inner pipe, 17
solvent cement, 16
template, 12
behavior, being cool, xii–xiii
belt buckle. See also Hunter character
back of, 93–99
button in middle of, 6–7
colors, 5
creating for Hunter character, 4–7
foundation layer, 6
gray primer, 7
MDF (medium-density fiberboard), 5
metal versions of, 100
outline, 5
replicating, 99
scroll saw, 6
shaping, 6
spot putty, 7
textured styrene sheet, 6
bends, in foam, 63–64
blackwash, applying, 230, 234
block mold. See box mold
blood splatter weathering, 239–242bolts
making visible, 54
using to attach straps, 250–251
Bondo
mixing with resin, 46
secrets of, 48
box mold. See also mold box
back of belt buckle, 93–99
peeling off prototype, 97
breastplate
making, 73–74, 77
raised pattern, 78
brush painting, 199. See also painting
brushed steel faux finish, 211–212
bubbles
adding vents for, 103
appearance in rotocasting, 138
preventing, 139
preventing in molds, 131–132
untrapping from rubber, 96
buckles, 249–250
bucks, explained, 156
burn marks and scorches, 237–238
burnt metal weathering, 238–239
buttplates, 260buttstock, building for Hunter’s rifle, 110–117
C
cam buckles, 249–250
carbon fiber, faux finishes, 218–219
cardboard
for drip wall, 137
using with Hunter helmet, 44
cast part
making, 99
prepping for painting, 150–152
removing from mold box, 116
trimming for painting, 150–152
cast products, 90
casting resin, using rice with, 98
castings
demolding, 98
explained, 89
improving, 131–132
catalyst, explained, 89
caulking edges with clay, 162
center release buckles, 249–250
chest. See breastplate
chip brush, using with resin, 45
clamping framebuilding for vacforming, 164–165, 169–170
explained, 156
for vacuum forming machine, 176–179
clamps, using with battle axe, 14–15
clay
caulking edges with, 162
oil- versus water-based, 158–159
sprue made of, 102
clay bed
building for mold box, 111
registration keys, 111
clay blob, adding to mother mold, 143
clay tabs, adding to parting wall, 161
CNC (computer numeric control), 81–82
codpieces, 260
cold casting metal, 99–100
compound curves in foam, 63–64
contact cement, using with foam, 60
contour gauge, using with Hunter helmet, 54
corners, in foam, 63–64
costume armor. See armor
cotton and canvas webbing straps, 249
craft foam, sourcing, 58
cube with notch, 3D model of, 30, 34
cup shape, making, 75–76curing gypsum products, 161
curing time, explained, 89
curves in foam, 63–64
cut-off wheel, using with mother mold, 146
cutting. See also relief cut
foam, 59–60, 63
shape of battle axe, 13
cyanoacrylate adhesives, 11, 15–16, 34, 42
D
dagger, 108
marking sides of, 102
mounted prototype, 101–102
prototype, mold, and cast part, 107
prototype removed from cut mold, 106
replicating, 108
sprue made of clay, 102
vents for bubbles, 103
degassing silicone, 122
demolding
castings, 98
explained, 90
prototypes, 97, 115
dents and scratches, adding to armor, 77–78
doe, explained, 90draft, explained, 90
drills, using, xii
D-rings, 249–250
drip walls, 137
from mother mold, 126
removing, 123
drybrushing, 225–227
duct tape
dummy, 64–67
using with foil, 74
dummy. See duct tape
E
ears, protecting, ix
elastic straps, 249
elbows
and knees, 258
shaping, 73
enamel paint, 194–195
epoxy paint, 195
EVA foam. See also foam
gluing straps to, 253
sourcing, 58
eye holes, rough trimming, 151
eyes, protecting, viii–ixF
fabric straps, 249
factory-looking parts. See vacforming
faux finishes
carbon fiber, 218–219
leather, 212–214
metal, 210–212
wood grain, 214–218
fiberboard. See MDF (medium-density fiberboard)
fiberglass
adding to mother mold, 142–143
brushing resin into, 125
gluing straps to, 253
laying over resin, 124
resin and Bondo, 46
warning about, 125
fiberglass work, doing for Hunter helmet, 44–45
field repair kit, 264–265
filler, explained, 90
Flap tool, using in Pepakura, 32
flat backside on back of part, 93–99
florist’s foam, using for forming bucks
flux capacitor, explained, 91
foam. See also EVA foamcontact cement, 60
corners, bends, and compound curves, 63–64
cutting, 59–60, 63
hiding seams, 62
joining seams, 60–61
lap joint, 62
melting and deforming, 63
reshaping by hand, 63–64
seams and joints, 61–62
for shin armor, 69
sourcing, 58
tracing template on, 72
using hot glue with, 60–61
foam armor
human model, 65
tools and materials, 65
foam strip, sizing for forearm, 71
foil
using duct tape with, 74
using with armor, 70
footman loops, 249–250
forearm, pattern for, 70–72
forming bucks, 156. See also molds
building, 157–162
designing, 156–157finishing, 162
molds filled with plaster, 162
placement of, 169
plaster print coat, 159
strengthening, 160
thickening mold with plaster, 159
forming platen. See also platen
placement of forming bucks, 169
using in vacforming, 166–174
for vacuum forming machine, 183–184
G
gang mold, explained, 90
gauntlets, 158
cutting pattern for, 70
matched pair of, 72
trimming, 78
gel and gel time, explained, 90
glass reinforced plastic, 124
glue
adhesion, 252
applying to battle axe, 11, 16
using to attach straps, 251
gluing
straps to EVA foam, 253straps to sheet plastics, 251–252
goos, using to attach straps, 251
gray primer
adding to Hunter helmet, 53
using for belt buckle, 7
using with wolf helmet, 83
gypsum products, curing, 161
H
hand plate, sculpting, 158
handlers, 263–264
handplates, attaching, 257–258
hands, protecting, ix
heat guns, using, xi–xii
heat sources for vacuum forming machine, 177–179
helmet. See 3D model; Hunter helmet
HIPS (high-impact polystyrene), choosing for vacforming, 163
hips and shoulders, 259
hole saw, using for battle axe, 10
hollow copies, making, 134
hot glue, using with foam, 60–61
hot knife, using to cut foam, 59
human model
duct taping, 66–67
plastic wrapping, 65space for legs and arms, 67
Hunter character. See also belt buckle
adhesive for binding sawdust, 5
belt buckle for, 4–7
forming shoulder for, 173
posing, 267
reference artwork, 5
Hunter helmet. See also 3D model; rotocasting; mother mold; rotocasting;
wolf helmet parts
3D model, 35, 43
appearance of bubbles, 138
avoiding errors, 42
building essentials, 40–41
building rows of ridges, 54
building up rubber jacket, 138–139
choosing place to begin, 42
concept art, 35
contour gauge, 54
crown parts, 38
cured print coat, 139
detailing, 53–55
drip wall, 137
fiberglass work, 44–45
filling holes with spot putty, 55
finding starting point, 37gluing pieces together, 42
gray primer, 53
making hard, 43–50
making paper shiny, 45
making smooth, 50–53
making waterproof, 46
mother mold, 140–147
nose parts, 42
painted version of, 152
preparing prototype, 135–136
preparing work space, 138
printing, 40
problems with, 134
rearranging seams, 38
resin, 44–46
resin/Bondo mixture, 46
rough trimming eye holes, 151
scoring fold lines, 42
seams and tabs, 39
shaping, filling, and sanding, 52
silicone registration keys, 140
thixotropic additive, 139
tiny parts, 40
tools and materials, 40–41
unfolding process, 39workbench, 44
Hunter’s rifle. See also three-part silicone rubber molds
barrel assembly, 24–25
bending sharp corners, 26
butt, 20–21
buttstock, 110
cutout for battery pack, 27
determining scale, 18–19
final assembly, 27–28
finishing, 131
forward body, 23–24
gluing pieces together, 27
holes drilled, 27
lights and electronics, 22–23
magazine well, 120
main body, 21–22
parts, 27
upper cover pieces, 25–27
Hydra, Liz, 187
I
ice cube tray, using for registration keys, 121
J
jack plane, using for battle axe, 9
jacket mold. See also mold jacketwith mother mold, 134
thickening, 126
jigsaw
using for battle axe, 9
using with battle axe, 8
using with Hunter helmet, 54
K
ketchup, using as masking agent, 228
keys, explained, 90
knees and elbows, 258
knives
keeping sharp, 59
using, x
Krix, Harrison, 187
L
lacquer paint, 195
lap joint, using with foam, 62
leather
faux finishes, 212–214
straps, 249
lungs, protecting, viii
M
magazine wellfilling with clay, 120
prepping for molding, 129
magnets, using with vacuum forming machine, 186
mannequin, building from duct tape, 64–68
masking agents, 228–229
masking tape
painting, 206
removing, 208
using for painting, 205–208
using with gauntlet, 73
using with shin armor, 69
materials. See tools and materials
MDF (medium-density fiberboard)
using for battle axe, 8
using for Hunter character, 5
using for Wolf Warrior character, 11
wolf helmet parts, 83
metal, 210–212. See also patina weathering
metal parts, simulating look of, 99–100
microballoons, adding, 116, 132, 149
mixing plaster, 160
model, explained, 90. See also prototypes
mold box. See also box mold
building, 103
for buttstock, 111clay bed, 111
coating with release agent, 114
demolded prototype, 115
demolding prototype, 106
disassembling, 104, 115
height of, 103
ink on outside of, 105
jeweler’s cut, 106
pouring in resin, 116
pouring rubber into, 104
reassembling, 115
relief cut, 104–105
removing cast part from, 116
serpentine cut in, 105
strapping together, 116
mold jacket, smoothing, 123. See also jacket mold
mold release, spraying on, 126
mold-making
material, 88–89
terminology, 89–91
molds. See also forming bucks; mother mold; multi-piece molds;
rotocasting
of clay, 88
explained, 90
filling with resin, 97–98peeling off prototypes, 97
piece with details on sides, 101–108
of silicone rubber, 89
sprues and vents, 112
mother mold. See also Hunter helmet; molds
adding fiberglass, 142–143
building for Hunter helmet, 140–147
building second half of, 128–129
clay blob, 143
clay parting wall, 141
completing, 125–126
explained, 90
holes drilled around flange, 144
jacket mold with, 134
mixing instructions, 141
prying apart, 129
reassembling, 147
relief cut, 146–147
wall coated with resin, 142
mud weathering, 230–231
multi-piece molds, making with mold box, 110–117. See also molds
mustard, using as masking agent, 228–229
N
necks, ankles, and wrists, 254–256notches, cutting into paper template, 75
nuts, using to attach straps, 250–251
nylon straps, 249
O
.OBJ format, converting models to, 30
one-piece molds. See Hunter’s belt buckle
P
padding
adding, 246
installing, 247
materials, 246–247
paint. See also basecoats; spray painting
alligatoring, 203
application processes, 196
applying, 200–201
blistering, 202
blushing, 201
brush marks, 204
compatibility, 195–196
crinkling or wrinkling, 203–204
elements of, 194
fish eyes, 203
grainy or bumpy surfaces, 202–203
hair, dust, lint, or bugs, 204masking tape, 205–208
problems and solutions, 201–204
sagging or running, 201
types of, 194–195
painting. See also brush painting
armor, 80
masking tape, 206
prepping armor for, 79–80
prepping cast part for, 150–152
trimming cast part for, 150–152
paper, making shiny, 45
paper template, making, 75–76. See also template
parachute buckles, 249–250, 259
parting line, explained, 90
parting wall
clay tabs added to, 161
making from water-based clay, 159
parts
for armor, 174
explained, 89
with flat backside, 93–99
sculpting, 158
patina weathering, 236–237. See also metal
patterns. See also template
bandage shears for forearm, 71forearm, 70–72
shaping, 68
template for shin armor, 69
test fitting for gauntlet, 72
peeling molds off prototypes, 97
pencil, rubbing with, 12–13
Pepakura Designer shareware. See also 3D printing; prototyping
adhesives, 34
Check Corresponding Face tool, 37, 40–41
downloading, 30
Flap tool, 32
gluing seams, 34
model parts cut out, 33
Print Page Numbers box, 40
print settings, 33
printing on cardstock, 33
scored line for fold, 34
PETG (polyethylene terephthalate glycol-modified), 163
photos, posing for, 265–267
pipe fittings, boring and shimming, 17
plaster, mixing, 160
plaster mold, prying apart halves of, 161
plaster print coat, 159
plastics, choosing for vacforming, 163–164
platen, explained, 156. See also forming platenpolyester resins, warning about, 44–46. See also resin
polystyrene, choosing for vacforming, 163
powdered brass, dusting mold with, 99
power tools, using, xii
primer
adding for rust weathering, 232
applying, 199–200
color, 228
print coat, pouring on prototype, 126
printing. See also 3D printing
3D model, 30
Hunter helmet, 40
Pepakura model on cardstock, 33
protective equipment, using, viii
prototypes. See also model
demolding, 115
preparing for rotocasting, 135–136
prototyping. See Pepakura Designer shareware, 82
back of belt buckle, 93–99
buttstock for Hunter’s rifle, 110–117
explained, 90
peeling box mold off of, 97
PVC pipe fittings, for battle axe, 17
Rrapid prototyping systems, 82
registration keys
adding to clay bed, 112
making from ice cube tray, 121
in silicone surface, 140
for three-part silicone rubber mold, 123
release agent
coating mold box with, 114
explained, 90
relief cut. See also cutting
making for mold box, 104–105
for mother mold, 146–147
resin. See polyester resins
covering with fiberglass mat, 124
filling mold with, 97–98
pouring into mold box, 116
resin cast parts, prepping for paint, 197
resin mixture, adding microballoons to, 149
respirators, wearing when painting, 198
rib piece, making, 76
rice, using with casting resin, 98
rifle. See Hunter’s rifle
rivets
and screw heads, 79
using to attach straps, 250–251Rondo
gluing straps to, 253
making for Hunter helmet, 46–50
rotational casting, explained, 90
rotocasting, 147–149. See also Hunter helmet; molds
explained, 90, 134
tools and materials, 134
rubber, pouring into mold box, 104, 113. See also silicone rubber
rubber gloves, using to make Rondo, 47–50
rubber jacket mold. See jacket mold
rubbing with pencil, 12–13
Rubin, Peter, 82
rust weathering, 231–235
S
safety equipment, selecting, ix
sanders, using, xii
sandpaper, using, x–xi
sawdust, binding with adhesive, 5
saws, using, xii
scorches and burn marks, 237–238
scratches
adding, 227
adding to Hunter helmet, 230
and dents, 77–78screw heads
making visible, 54
and rivets, 79
screws
driving for battle axe, 12
using to attach straps, 250–251
scroll saw, using for belt buckle, 6
sculpting parts, 158
seams
gluing for Pepakura model, 34
hiding in foam, 62
joining for foam, 60
making in foam, 61–62
and panel lines, 77
sheet plastic
bending sharp corners in, 26
gluing straps to, 251–252
shield for Wolf Warrior, 80
shin armor
masking tape, 69
template for, 69
shoe covers, attaching, 258
shoulders
forming, 173
and hips, 259silicone rubber. See also rubber; three-part silicone rubber molds
for box mold, 95–96
cleaning up edge of, 124
degassing, 122
making molds from, 89
pouring, 96
untrapping bubbles in, 96
slide adjusters, 249–250
slush casting, explained, 90, 134
snaps to undersuit, 248
solvent cement, applying to battle axe, 16
space heaters. See heat sources for vacuum forming machine
spin casting, explained, 90
spot putty
using for belt buckle, 7
using with Hunter helmet, 55
spray painting, 199. See also paint
spring clamps, using with battle axe, 14
sprue
explained, 90
made of clay, 102
and vents for mold box, 112
.STL format, converting models to, 30
strap harness, 248
strappingdesign considerations, 253–254
materials, 249
tips, 260–261
straps
attaching, 250–253
gluing to sheet plastics, 251–252
gluing to fiberglass and Rondo, 253
poking holes in, 251
styrene layers, holding together, 15
styrene sheet, using for belt buckle, 6
subtractive weathering, 227–230
T
template. See also patterns
for 3D model, 31
for forearm, 72
for shin armor, 69
tracing onto foam, 72
using with battle axe, 12
textured styrene sheet, using for belt buckle, 6
thixotropic additive, using with Hunter helmet, 139
three-part silicone rubber molds. See also Hunter’s rifle; silicone rubber
clay bed, 119–120
jacket halves, 130
mold release, 126print coat, 121
prototype, 118–119
registration keys, 121, 123
removing clay, 127
removing drip wall, 123
thickening coats, 122
tools and materials, 118
tools and materials
armor, 58, 70
bar clamps, 10
chip brush, 45
drills, xii
foam armor, 65
forming bucks, 157–158
heat guns, xi–xii
hole saw, 10
for Hunter helmet, 47–50
Hunter helmet, 40–41
jack plane, 9
jigsaw, 8
jigsaw blade, 54
knives, x
power tools, xii
rotocasting, 134
sanders, xiisandpaper, x–xi
saws, xii
screws, 12
scroll, 6
spring clamps, 14
three-part silicone rubber molds, 118
two-part mold with mold box, 110
utility knives, x
two-part mold, 110–117
U
undercut, explained, 91
undersuit
snaps to, 248
Velcro to, 247–248
urethane casting resins
adding filler for, 116
availability, 147
curing, 149
warning about, 98
urethane paint, 195
utility knives, using, x
V
vacforming
building clamping frame, 164–165choosing plastics for, 163–164
forming bucks, 156–157
forming platen, 166–174
layers, 173
machine, 156
process, 156
terminology, 156
warning about, 156
vacuum chamber, 96, 122
vacuum forming machine
clamping frame, 176–179
configurations, 180–183
forming platen, 183–184
grid for platen, 183–184
heat sources, 177–180
rare earth magnets, 186
toggle switch for heater, 187
using, 188–189
vacuum sources, 184–187
warning about, 176
Velcro, adding to undersuit, 247–249
vents
adding for bubbles, 103
explained, 91
verisimilitude, explained, 221viscosity, explained, 91
Vitruvian Hunter, 245
W
washes, adding, 222–225
weathering
additive, 222–226
blood splatter, 239–242
burnt metal, 238–239
drybrushing, 225–227
mud, 230–231
patina, 236–237
rust, 231–235
scorches and burn marks, 237–238
subtractive, 227–230
washes, 222–225
wingnuts, using with molds, 130
wolf helmet parts, 83–84. See also Hunter helmet
Wolf Warrior character
battle axe for, 8–18
shield for, 80
wood grain, faux finishes, 214–218
workbench, for Hunter helmet, 44
wrists, ankles, and necks, 254–256
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