talk.nerdy2.me

Use the Spice, Paul!

[michmedia]

Been awhile; life has thrown me some curveballs over the past two years, but I think I’m getting inspired again to finish this project. Looking over reference photos, I was heartened at how close my armor is to them at least visually, and I know the measurements are there to back my eye up.

So I spent a couple of hours the other day picking up where I left off and chiseled the sides down by about 2cm on my torso models where the molds had opened up. They all need overall smoothing, undercut removal and final proportion adjustments, but they’re nearly ready to go on the vac table. The helmet is another matter, but I know the process, having done the various mold-making steps previously.

I just need to dive in and keep at it. That’s how I made progress before; caffeine and pain killers.

[michmedia]

Chest model is re-done! Despite not having had my hand in this stuff for a long time due to life stuff, all of my processes and tricks came back together again and I’m fairly pleased with the result. The shape is certainly MUCH closer to what it should be; I’m not sure how I missed that the first time around. Now I really just have the helmet mold left to make, and that will probably take a couple of weeks, realistically. Hopefully I can keep momentum now that I’ve done some more work on this again. Thanks to my buddy Z for the creative nudge!

[michmedia]

Stock Ordered

I just ordered some rolled sheets of styrene of the correct thickness to vacuum-form, which will hopefully motivate me to get the remaining molds made. I only have to pour the chest re-do (easy; 1-day), then make the helmet mold, which will be a multi-part doozy, consisting of: silicone impression mold reinforced with elastic, and a 2-part plaster "mother" (rigid shell) around that, perhaps reinforced with cheescloth. Once THAT is made then I can pour plaster positives (to pull helmet halves on my table), or slush cast a full helmet in some kind of epoxy/resin, or both. I think I'm going to seal the plaster model with glue before I make the mold. It's a commitment that I'm done tinkering, but it will protect the surface.

[michmedia]

Voltage regulator arrived! I blew the onboard fuse when I tested it at ~90v and I was concerned that I was back to answer B (see below). But I replaced the fuse, and did another test, this time starting at 30v, and gradually dialing up the voltage by 5v increments. I got up to 60v before I shut it down, having run for the longest it has yet at several minutes continuously. I have no doubts now that the oven can operate safely and continuously as intended.

The element coils were not glowing, but they were giving off heat akin to infrared bulbs, which is what I need to soften the plastic sheets. My next test will be to put a thermometer in there to read actual temperatures, and I’ll probably also continue to bump up the voltage to see at what point it blows the fuse.

My flexible chest mold also released with minimal sticking to the model, preserving both, which is fantastic. I didn’t coat the model with any kind of mold release prior, and only lightly spritzed the outside with water to encourage good internal expansion of the foam, which I mostly got.

[michmedia]

I think I found the culprit to the poor connection in the outer circuit; replaced with a much cleaner screw (though it still trips the breaker); voltage regulator should arrive tomorrow. I made a new foam mold for the corrected chest plate just now—and used an entire large can of foam insulation to do it! 😳 I almost didn’t have enough; I think it will expand when curing and be okay.

[michmedia]

It worked… perhaps a little too well, because it tripped the 20a breaker after about 10 seconds of running. 😩 So I ordered a voltage regulator and I’m hoping that does the trick. I’m also trying to figure out why the outer coils aren’t as orange; I need to make sure they aren’t touching anywhere as I see they are at the top (the coils expand a bit when heated), and I want to check the terminal connections on the bottoms of the posts, as well.

[michmedia]

I didn’t take many progress photos today because my phone was charging and I was in the zone, but I wired the oven today—which was a major hurdle for me—and also did a test, which was partially successful. So, the oven I made based on the instructions I followed should draw about 20 amps. With this in mind, I put the appropriate gauge wire and switch into the wiring.

My house is mostly wired with 15 amp breakers, save for a couple of locations. One of them is in the far corner of my basement, where a washing machine used to be. So, after tripping several breakers trying to find the 20 (the breaker box isn’t labeled very clearly, either), I finally ran an extension cord from the basement to the garage, flipped the switch and the oven stayed on! Coils started to glow orange!

The reason for success being partial is twofold: 1) I need a heavier-duty extension cord rated for 20 amps, and 2), the connection on the non-terminal posts needs to be improved. I’m going to try wrapping the posts (screws) in copper wire to increase surface area to the connection with the coil. So, once the heavier-duty cable arrives in a couple of weeks I’ll run another test and take pictures of the oven running. What’s funny is that originally I was sent the wrong item-a 20 amp outlet instead of a switch. As it turns out I will need that outlet to update the one that’s currently there to use the new extension cord, due to the plug shape.

[michmedia]

Been a looooong time since I’ve posted here; too long. Life happened for awhile, moved to a new house which took about a year, all told. The upshot is I have more hobby space, and I’m getting time back now, as well! Here’s where the table’s at; it’s nearly done now. You can see I have the oven mounted on the chassis with the forming table and clamping frame, and how the latter pivots to alternate between both locations via a handle, which I installed and which you can see in these photos.

Part of the delay was that my helper sort of bailed on me when we got to the oven, so I had to fabricate that by myself completely and learn how to wire it based on cryptic instructions, but I think I’m ready now to wire it up. I have all the parts I need, and I don’t think it will actually take more than a day or two. I’ve just never done this before (not that that’s stopped me yet).

In terms of models and molds, I had to pull apart and re-form the wire chest plate model due to inaccuracies, but I now have that put back together and ready to make a foam mold of, into which I can pour a plaster positive for the table. The helmet also needs a to have a mold made of it. I have all the materials needed to make it, I just haven’t had the time up until now. It’s going to be a big, challenging mold, using silicone, elastic, and a plaster mother, but once that’s made I’ll be able to duplicate it in various methods and mediums.

[michmedia]

A Tentative “OK”!

At the request of my helper, I shared the oven plans and my understanding of them with an electrician acquaintance through work. I had to do some learning to be sure I understood it and was asking the right questions, which was good to affirm for myself, but today I heard an initial response back which was even more heartening.

Of the possible responses, A) no response, B) you have no idea what you’re doing; do not attempt, C) yes, this looks correct, D) here’s how I would do it, I have preliminarily gotten C, with possibly more info forthcoming. I feel validated by this and I am tentatively excited as this green-lights the final step in the vacu-form table construction as responses A or B would not have.

[michmedia]

Vacuum Test Success

I neglected to take any photos, but this past weekend we performed a test of the vacuum system (pump, tank, gauge, valve, forming platform), which was successful! We used heavy plastic film to simulate pliable plastic sheets, and the system worked as intended, molding the plastic down over a form. Super-exciting! Once the oven is wired the vacu-former will be ready to use.

[michmedia]

Progress Update

I’m progressing on multiple fronts; planing down the sides of my plaster torso molds, and today I worked more on the vacu-form table. I got the plumbing mostly connected, and am ready to connect the forming platform once the bottom half is sandwiched to the top. Then really all that’s left is to wire up the oven and it should be functional! I need to look into ordering plastic sheet stock.

[michmedia]

I noticed too late (after pouring plaster) that my foam molds had opened up a bit from their initial curvature, adding an additional inch on both sides to the plaster models. After going back and forth for a bit, I decided that the easiest fix is just to plane down the plaster on the sides, since it’s just a simple curved surface. The plackart now nests properly inside my newly remodeled breastplate, as you can see. I still need to plane down the excess on the corresponding rear plates (a day or so) make a new foam mold for the updated breastplate and re-cast the plaster model.

[michmedia]

In looking at reference photos I took at the Star Wars: The Art of the Costume exhibit I’m seeing some places where my models aren’t as accurate as they could be. The most glaring was the breastplate, the top of which was far too flat and the angle at the pectoral ridge far too acute. So yesterday I carefully separated the two halves my original wire mesh breastplate model, bent them into better shape and re-attached the halves today. As you can see, the shape on the upper portion is much more rounded now than it was, better matching reference photos. I also have to shave down areas on my other torso plates, and the calves, at least; possibly vambraces, also.

[michmedia]

Plumbing for vacuum system, purchased today. Not pictured (but extant): air tank and forming platform.

[michmedia]

The vacu-former is finally taking shape. I had to make the 441 holes larger, and I punched 1/3rd of them today. I am tired; another day of work ahead tomorrow.

[michmedia]

Progress

I worked with my helper today for a couple of hours tracking down fittings for the vacuum component of the vacuum-forming table. We found about 80% of what I needed, though most of the fittings needed to be sandblasted, which I did. We have a shopping list for the remaining parts and we’re going to continue working tomorrow.

[michmedia]

Oven is done. Today I made the temporary wall lashings permanent, and fitted in the corner blocks. Next step is putting it on the cart chassis and wiring it up electrically, which will require some assistance from a helper.