The Acrylikhan Armor Project Files

[Acrylikhan]

New forum, fresh start!

 

Still working on the forearm piece. Got back to gluing some general shapes together for cutting later.

 

 

 

 

I know, I know... really crude looking, but that's sometimes how things evolve.

 

I am planning to cut the end piece, after I look over my measurements again, and then either use bondo, or epoxy putty to make that gentle slant from the bottom layer to the top. I did find a problem... that raised section (the beige piece in the center) is not perfectly shaped as it's supposed to be. I have to figure out how to fix that. Probably bondo, and then shape with a piece of curved plastic.

 

I think the raised section and the lower section need to be closer in thickness the closer to the webbing slots they become. So there will be some major usuage of the disc sander within the next 48 hours. What do you guys think?

 

I am going to start the belt, thermal detonator, and thigh boxes very very soon... due the easy of some of the construction. The "buckle" piece looks interesting and should be fun!

 

If I make a breakthrough tomorrow, I'll post more pictures very soonly!

 

Thanks for your support and feedback. It's making everything better each time I make alterations.

[Imperialgrrl]

Looks like the general shape is coming through - I can't wait to see the finished piece!

[Arcturus1020]

It's crap, Frank. You better give it to me when you're finished with it so I can dispose of it properlly.

 

Looks good so far, man! Keep the updates coming.

[TB-7076]

I'd broaden the middle elevation a bit. This is the mistake all but MonCal's elbows have. Too slimm T-ends and round top while being a bit borader and at the frontend quite edgy in the bow.

[Acrylikhan]

Ok, that sounds good! I'll tinker a bit more with it.

 

 

 

The cuts and sanding I made today have mishapen it a little bit. So I may debond the sections and retool it.

 

Thanks Again, everyone!

 

- frank

[Acrylikhan]

I am starting over on the forearm/elbow armor. I keep looking at the pictures and I see something new everytime. More on that later...

 

I am starting the hip boxes and the belt today and tomorrow.

 

Is the body facing side really contour curved to the hip area? I look at SC's armor and the movie stills, and I don't believe that they are, or supposed to be. Also, could the belt boxes attach to the belt with Alice clips? Which brings me to my next pondering: is the belt half plastic/half webbing?

 

Still looking for proof of any kind... Does anyone have good close ups of the scout uniform that was on display during the expo?

 

I am also tinkering around to make these boxes functional. Maybe a living hinge with a spring loaded locking tabs. Probably will use a softer urethane so the hinge lasts.

 

I'll post some drawings soonly.

 

- fk

[TB-7076]

Yes contour is curved:

 

 

Yes belt is hard parts front and canvas/poly webbing belt aft

 

Yes 2 Alice clips are in the back of the belt and two zip ties

weather both items hold the detonator/regulator whatever is not clear but on of these probably does. You can distinnct alice clips and zip ties by the way they shine in the photos (Alice clips stick out more while zip ties are very tight to the belt)

 

Just go to the gallery into the mom section and you'll see. (However due to the information one guy did heavy patching to the exhibition piece people look at these with twisted views - I see it realistic. There probably wasn't done any major harm to the general look/shapes)

[Acrylikhan]

Again, you teach me much! I started assembling the boxes out of acrylic plastic today. I will sand blast them tomorrow if I can complete the assembly, and prime them. A new big job came in at work, so I may have to regulate the boxes to my lunch half-hour.

 

Back to the forearm a moment;

 

 

This picture has been bugging me. It looks like that even though the piece is generally a cylinder, I'm constantly seeing these "facets" in shots with good contrast. Mainly screen captures were the actors were shot on blue screen. But then this picture makes it look cylindrical.

 

 

I'm thinking that the facets might not be as pronounced as I think, and the contrast is just an optical effect bringing out the edges.

 

I'm thinking something a section of an octagon?

 

-fk

 

P.S. Oh, yeah... the website is up: check it out! Especially my projects page.

www.frankkrug.net

[Guest Thallion]

This is just my opinion here, but it is entirely possible there were multiple different styles made during prototyping, then x many of the correct suits were made, then they either accidentally used the wrong suit (or one wrong piece) one day, or the correct one was in transit from one shooting location to another, so they improvised, or who knows what else. The forest scenes were shot in california forests, but wasn't the blue screening done in london, or even if in california, maybe the suits were still in transit. ANyway my point is maybe this is another one of those flub ups that 99.99999% of the people would never notice so they just used what was on hand when (if) they realized it wasn't the same piece of the suit used during the outdoor filming.

 

Anyway my point is, your observation appears right to me that speeding bike blue screenshot looks angular, and the suit in the exhibitions and such IS round.

 

Well thats my opinion anyway.. I know that doesn't help, but I would stick with the round as it is the commonly accepted suit. And you know if you make it angular that costume snobs will tell you your suit is wrong, and then you have to whip out the well, look at time xx:xx:xx in chapter x of ROTJ and you will see ... ugh I hate it when people are like that...

[TB-7076]

That is an optical trick.

1st. both pictures show a slight different angle/perspective.

2nd. if you throw contrast in the mom shot you have a similar effect

3rd. both observarions angular and round are correct.

 

The shape of the elbow must be seen like an egg shaped oval upside down the narrow tip being downside seen from the front. The front end is more angular but not completly.

 

[Acrylikhan]

Pictures!

 

 

 

 

 

 

My happy little family of masters grows! The shoulder bell is finished!!!!

 

TWO DOWN!!!! MUUUUWAHAHAAHHAHAAHAHAHAHAHAHAH!!!!

 

I started the belt boxes. These are the two outer boxes made from acrylic sheeting and acrylic bonded. I'm very confident about them staying together. My buddy at work decided to throw one of them across the shop. Amazingly... it held together and didn't shatter. Well, he disproved my thoughts that it would break. I have to square the corners, and them round them over. I will be sandblast them so that I can prime them, and then ultimately paint the parts.

 

 

I should be able to start the inner boxes tomorrow. The "buckle" I'm still generating a plan at the moment.

 

I have a piece of ABS that I will be using for the hard part of the belt. Instead of rivetting the webbing to the plastic, I have an idea. Plus this would make the belt a signature piece. I think our Pathfinder Commander would approve!

 

 

First, Making a notch in the end of the belt.

Second, make a second notch "across" the first, at half depth of the material thickness.

Third, take a piece of aluminum (or steel) stock that will fit in the cross cut.

Fourth, make a custom topper to bond to the main body piece. Thereby encasing the aluminum, and making a nice "bar" for the webbing to wrap around and stitch it in place. The topper would add strength to the section.

 

Madphisto, Thanks for clarifying for me. I like to be sure, especially when my eyes start crossing from staring at a the monitor all weekend.

 

Thallion, Please keep the comments coming in! I welcome all opinions, and ideas! Feel free to leave a critique with what you think! I agree with the manufacturing variations that can happen in a movie model shop, especially if deadlines are looming, and you have thirty more fuill costumes that need to be produced. I think that's what makes this project fun. You can follow closely to the pictures, but little things that make your costume stand out from the crowd make all the difference.

 

BTW, I got the ol' girl up and running. That be my website. I started writing thoughts and posting pictures with my progress on the suit thus far. I've got two sections up, and an intro.

Some familiar screen names here at bikerscout.net are in the Thank you section. Take a bow! you deverse it!

 

Take a visit @ www.frankkrug.net Click on the Projects section, and look for the tell tale picture for the link to the scout section.

 

Time to tackle the thermal denotator.

 

Thanks for stopping by, and have a good night!

 

-fk

[TB-7076]

Very nice page and cool art!! Love the way you wrote the tutorial - quite entertaining

[TB2849]

I love the bicep pieces. they look so crisp and clean! way to go man great job!!

[Acrylikhan]

Thanks! It was a lot of patience, sanding and priming. I should have more for you guys soon!

 

-fk

[Acrylikhan]

Started fresh on the forearm armor. I removed the "collar" from the elbow section, and re sanded it. I got some scrap pieces and put them on the collar. It's still a bit short, on one side, but totally fixible. I love being a master at this!

 

I am working in reverse of my original plan. I'm doing the bottom layer first, and then top ridge piece. I started mapping the cuts I hope to make tomorrow. It's not at full length of 16 centimeters (I've scaled this piece to accommedate my orangutang-like arms).

 

 

 

I'm researching the torso armor. Was the backplate and the front plate the same, except for being trimmed differently?

 

Made a GROSS error on the belt boxes! I forgot their curved! I'll see if I can salvage the ones I made last week. I think I can... so I am optimistic!

 

- fk

[Guest Don Jarr]

Hi m8

 

For the chest and back armour details, check out the MOTM pictures in the gallery, and you will see the bottom lip bit on the front plate is concave, and the bottom lip on the back is convex. It will make more sense if you look at the MOTM pictures.

 

Looking good though m8

 

Don

[Acrylikhan]

Hi m8

 

For the chest and back armour details, check out the MOTM pictures in the gallery, and you will see the bottom lip bit on the front plate is concave, and the bottom lip on the back is convex. It will make more sense if you look at the MOTM pictures.

 

Looking good though m8

 

Don

 

 

DON!!! Good to see you again. That T-bit worked out great on the bicep armor! Big thank you!

 

I will check out the MOTM pictures again. I'm getting ready for one of the biggest tasks of the entire armor set! Well... that is if I decide to scratch buidl a helmet!.

 

- frank

[Acrylikhan]

Progress!

 

Date: 2006.05.12:

 

 

Finished finalizing the the "bottom" armor layer. I traced out where the "ridge" part is going to be placed.

 

 

Nice Side view for ya!

 

 

And a frontal shot too!

 

 

This was a tough one to get the curve just right. A lot of trial and error with a marker. Then I dremeled out the sections I didn't need.

 

 

I just realized, I've never shown a backside of any of the pieces. This is a pretty good example here. Not pretty... a jigsaw puzzle of scrap plastic bonded together. You really wouldn't want to wear a part that was held together with just styrene cememt. If you do not apply it properly, it can become a weak point for breakage. This is good enough for a master, as the part will be molded in silicone. This part I may make an exception to finish the inside. You might be able to see the backside.

 

 

Next step is adding the ridge detail and sand in a very gentle curve to the main body. Then pattern finishing to smooth the surface. I will be cutting in the slots for the webbing too.

 

Hopefully, I will be able to get more work done this weekend! More to come.

 

-fk

[TB-7076]

Really nice work. Awesome puzzle work - it's fascinating to see how that still works together. When you are finished you will have a very nice piece and and quite a monument for determined labour.

[Acrylikhan]

NEW PHOTOS - PROGRESS!!!

 

enough words... lets get those pictures up!

 

 

 

 

 

 

 

Ulp! Photo 66!

 

 

 

 

 

Hey Madphisto! It's starting to look like your CAD drawings! Your drawing and the MoM pictures really ROCKED! It made this step easier after I slowed down and looked at everything carefully, and then executed. My thanks again to you!

 

Stage one is complete! I finished the lower tier of the armor, and then sculpted out the top tier that overlays the top. You can see from the very last picture above that you can see some of the light in the middle of the part. That will soon be covered with bondo to strengthen the area. The ending thickness in that area will be close to an eigth of an inch (about 3.25 mm I think....) I will probably cut out the slits for the webbing... they will be about an inch wide (2.5 cm) I will be using body filler to make the nice smooth edges were the top tier and lower tier meet. The inside will have the same, for added strength, and esthetics. This is the only piece that I am finishing both the top and inside. I figure, with all the arm movement, the inside part might be visible with all the arm waving, action poses for the camera...

 

Not to brag... so far all three arm pieces (Shoulder, bicep, and forearm) I've worked on, total cost has been USD$5.00... that includes superglue, kicker, and body filler. Recycling and puzzle-working scrap styrene helped TREMENDOUSLY with keeping the cost very very low for the master making process.

 

Hopefully I'll have more photos next week. I am working on the "Thermal Detonator," and the boot holster.

 

- fk

[Acrylikhan]

Lots of work done this weekend. The arm masters are nearly complete. If I can get molds ready by August, I could have a set done... and possibly have a few for ebay.

 

Enough dreaming though... here's reality:

 

 

Thermal detonator housing is started! I used 1/8th-inch Acrylic sheets cut to size and then glued together.

 

 

I used styrene to cut the shuttle. This side glued inplace without a hitch.

 

 

This side crazed after I hit it with some kicker.

 

 

A little bondo and sanding things look really good.

 

 

Then primed it. More picts below:

 

 

 

 

 

 

More to come.

 

- fk

 

Back to the forearm armor.

 

 

I took a layer of primer to get see the flaws and dings from assembly of the top layer with the bottom layer. you can see the curves of the top layer "tongue" are not symmetrical. Quick work with a dremel restored a proper curve. It's body filler time.. so I started with the backside first.

 

 

Before and After

 

 

A little more fine tuning and it will be smoother than a baby's butt.

 

Top side, I patched the curve areas with bondo. I let it dry and then smoothed out one side to get the proper angle.

 

 

Then sanded the other side as closely as possible.

 

 

More orthos:

 

 

 

 

 

 

Much more to come!

 

- fk

 

(P.S. Madphisto... I stole your percentage complete idea you use for your icon. It's a great idea!)

 

 

 

So here's my completed masters thus far:

 

 

 

We are almost @ 8% complete!

 

 

- fk

 

 

By the Emperor, this is taking long....

 

I have started the knee armor this morning. Mostly cuting plastic for now, but I am concerned over the angles. To me, the sides of the bottom stretch back at a 22.5-degree angle. The top part of the front of the knee armor is bent at an angle of 45-degrees.

 

Sound right?

 

-fk

[Acrylikhan]

 

Showin' off....

 

 

-fk

[Imperialgrrl]

Wow!! That's looking fantastic!!!

 

My only feedback is that the shoulder bell looks a little smaller than I'm used to seeing them - that doesn't mean it's off though, but that's just my .02!

 

I can't wait to see more!

[Acrylikhan]

Thanks Imperialgrrl..!

 

I did make mine a bit shorter and a different shape than the 8.5 inch (21.5 cm) from the SC armor. I used SC's mechanicals from his site as a starting point, but then used the Star Wars Choricles book and kinda guessed at the size. I went with 7-3/4 inches, and it looked right.

 

Then again... I am a mutant. I have orangutang-like arms!

 

- fk

(Swinging from tree to tree of the great Sesachewan Forests)

[TB-7076]

I agree with Impgrrl - Shoulder bell should extend a bit to the sides. Contrary to the slim shoulder bells of the troopers the scouts have quite large shoulder armor.