postmortem01 Posted December 8, 2009 Share Posted December 8, 2009 We've finally started the CNC stage of this project and things will start to move quickly here. Below you can see the chest mold master as it came out of the CNC. We are using a dense foam to capture sharp edges and detail. There will still be a bit of sanding and work to do after they are CNC'd but the quality and accuracy will be spectacular. I can't wait! Link to comment Share on other sites More sharing options...
Guest Skupilkinson Posted December 8, 2009 Share Posted December 8, 2009 I thought I'd already posted a reply this morning?? Oh well, that chest piece looks fantastic! Very smooth and clean, I'm very envious of you guys with access to CNC technology! Link to comment Share on other sites More sharing options...
postmortem01 Posted December 8, 2009 Author Share Posted December 8, 2009 We just bought a small CNC router. This will makes things much easier and cleaner. I hate sculpting with foam. The CNC loves it though. We're going to run the back and shoulders this weekend. Stay tuned! Link to comment Share on other sites More sharing options...
mrbungle Posted December 8, 2009 Share Posted December 8, 2009 nice. i have been looking forward to seeing the progress on this project ever since you guys first posted. i really want to see the helmet and how you guys do the backplate and tank. keep up the good work. Link to comment Share on other sites More sharing options...
Guest Skupilkinson Posted December 8, 2009 Share Posted December 8, 2009 Absolutely! You HAVE to put more videos up! I could watch that being CNC'd all day long! I'd kill to have tools and tech like that at my disposal! LOL! Link to comment Share on other sites More sharing options...
postmortem01 Posted December 8, 2009 Author Share Posted December 8, 2009 Yeah. The tank and backplate are looking like they might cause a bit of an issue with such a tall draw. Currently, it works out to about a 13" tall draw. We will need to add some adjustment length into the draws as well otherwise these will not fit anyone. As far as the height issue with the backplate and tank, we're going to try to pull this on a very strong vac former with a quick pressure dump. We'll see how it does. Link to comment Share on other sites More sharing options...
Lonescout Posted December 9, 2009 Share Posted December 9, 2009 Very impressive!....keep posting the vids....very smooth & clean! Link to comment Share on other sites More sharing options...
postmortem01 Posted December 9, 2009 Author Share Posted December 9, 2009 I'll shoot some videos this weekend. You can see in these pictures about how tall the draw will be. The other problem is the tank has a recessed area at the top for a control panel. This area may need to be cut in for a panel to be inserted from below depending on how this back is pulled. Link to comment Share on other sites More sharing options...
mrbungle Posted December 9, 2009 Share Posted December 9, 2009 i had to make my backplate in 2 peices. and i added the recess for the control panel. my pull would have been over 13 inches and there was no way i could pull that on my table. another problem i had was a one size fits all thing. the KT chest and back armor is small in comparison with clone armor. so my stuff fits smaller guys better. the bottom needs to over lap the front on the chest and back and the tabs at the top need to meet. Link to comment Share on other sites More sharing options...
postmortem01 Posted December 9, 2009 Author Share Posted December 9, 2009 We can pull the 13" in one shot but I'm a bit worried about webbing. on the corners of the tank. The tops of the shoulders are currently correct but the rib cage sides are sized for a clone. This means it's sized for a very thin man or a woman. (no offense intended to anyone) The rib cage overlap will be extended by a couple inches before we finalize the master. This will allow for a larger rib caged person like myself. Link to comment Share on other sites More sharing options...
slavefive Posted December 10, 2009 Share Posted December 10, 2009 Since when did we start this project again Kidding aside this project will be very fun to do...the CNC will make things go quickly and most of all as accurate as possible... Laters Lewis Link to comment Share on other sites More sharing options...
Acrylikhan Posted December 11, 2009 Share Posted December 11, 2009 Keep us in the loop! Link to comment Share on other sites More sharing options...
postmortem01 Posted December 11, 2009 Author Share Posted December 11, 2009 There will some pictures of the backplate and tank this weekend. I'm looking forward to cranking this out. I've hurt my back so I'm on restricted movement right now but we should be able to cnc the parts. Link to comment Share on other sites More sharing options...
Guest Skupilkinson Posted December 11, 2009 Share Posted December 11, 2009 Excellent! Can't wait! Hope your back is Ok bro. Link to comment Share on other sites More sharing options...
postmortem01 Posted December 14, 2009 Author Share Posted December 14, 2009 I didn't have much time this weekend so I CNC'd the backplate only. We'll cut some of the other parts out this week. I had to use two different types of foam since the green foam didn't show up. Bummer. The yellow sculpting foam is crap. I hate it. It's very much like using floral foam for your sculpting.....you shouldn't do it. Floral foam is cheap but the worst type of foam to use for sculpting. You can see that this would tend to be a bit of a tall draw. We've added another inch on the bottom to increase the amount of side reach you have. This should allow for some of us non-twiggy guys. Link to comment Share on other sites More sharing options...
mrbungle Posted December 14, 2009 Share Posted December 14, 2009 looking good. HEY leave us skinny cats alone!! on a side note, what is the green sculpting foam called??? i am using floral foam right now for my odst build and it does have it draw backs. Link to comment Share on other sites More sharing options...
Acrylikhan Posted December 14, 2009 Share Posted December 14, 2009 Are you guys designing the under arm straps of the back plate to go over the front armor straps as seen in the promo and other photographs? Link to comment Share on other sites More sharing options...
Acrylikhan Posted December 14, 2009 Share Posted December 14, 2009 That green foam looks awfully familiar.... 10-lb polyurethane sculpting foam? It looks like what I used for my scout holster buck. Link to comment Share on other sites More sharing options...
postmortem01 Posted December 14, 2009 Author Share Posted December 14, 2009 The green foam is a material called Renshape 5025. It's significantly more dense than 10lb foam but a bit more work to sand it smooth. In some cases, the Renshape is easier to work with though. The density makes it capable of holding high detail. It's much easier to seal as well. You can actually do test pulls over the top of it without destroying it before it is sealed. The side closure looks like this in the movie but I don't really see how this will be a good practical solution to wearing a costume. Link to comment Share on other sites More sharing options...
postmortem01 Posted December 14, 2009 Author Share Posted December 14, 2009 The Renshape is relatively inexpensive by comparison to 7 or 10lb sculpting foam. You can get a 48" x 96" x 4" board for about $1000 +tax. That would do the whole set of armor....pretty much. Link to comment Share on other sites More sharing options...
mrbungle Posted December 14, 2009 Share Posted December 14, 2009 The green foam is a material called Renshape 5025. It's significantly more dense than 10lb foam but a bit more work to sand it smooth. In some cases, the Renshape is easier to work with though. The density makes it capable of holding high detail. It's much easier to seal as well. You can actually do test pulls over the top of it without destroying it before it is sealed. The side closure looks like this in the movie but I don't really see how this will be a good practical solution to wearing a costume. i thought the same thing in my build, the little strap would be dragging against the bicep pieces. thanks for the info on the foam. Link to comment Share on other sites More sharing options...
postmortem01 Posted December 14, 2009 Author Share Posted December 14, 2009 Yeah. It's great to be accurate but this clasp is a bit silly. It's a horrible real world design... Link to comment Share on other sites More sharing options...
Lonescout Posted December 14, 2009 Share Posted December 14, 2009 keep the pics comming....I like that back-plate and hump! I am planning date with this armor. It may be an expensive one! Link to comment Share on other sites More sharing options...
postmortem01 Posted December 16, 2009 Author Share Posted December 16, 2009 Of course. More pictures to come before the weekend. We will also have pictures of the helmet, the tactical cummerbund and the glove mod. I'll keep this thread updated. My back is still out but I will be able enough to keep CNC'ing the masters. If there are any issues that you guys can forsee, comments and suggestions are welcome. Link to comment Share on other sites More sharing options...
TK412 Posted December 16, 2009 Share Posted December 16, 2009 Nice stuff man. Is the regular clone project dead? . Link to comment Share on other sites More sharing options...
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