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Duke's Custom Reach Suit Pep +photos!! *COMPLETE*

Discussion in 'Halo Pepakura Costumes' started by PerniciousDuke, May 24, 2016.

  1. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer


    Steps for Fiberglassing (post 2 of 3)
    Please understand that Fiberglass Resin does not contain Fiberglass.. You have to buy fiberglass separate.

    a. Get your materials ready. There are two main kinds of fiberglass, cloth and mat. Cloth contours to tight spaces better and is more expensive. Mat is great for large flat areas. I use cloth, both are pictured. Cut out various sizes and shapes of the fiberglass so that you can quickly lay them down.
    b. Be safe! Gloves are very important as fiberglass can leave micro cuts and results in irritated skin. Keep extra gloves easily accessible. Long sleeves are preferred along with glasses and a respirator.
    c. If your piece is pretty strong go ahead and remove the support beams. If you can work around them then you might as well keep them in to ensure better shape once it is done hardening the fiberglass.
    d. Spray adhesive from a craft store can save you a lot of frustration. The spray will help hold the material down so that you can cover the entire interior in fiberglass. If the next piece overlaps you'll need to spray more adhesive. You will want the fiberglass to be completely glued down. If you're having trouble with the fiberglass sticking to your hands just change out your gloves.
    e. Lay the fiberglass so that it contours to the piece. You do not want gaps between the pep and the fiberglass. Also try to get each piece as close together as possible. Overlapping is better than barren spots. Also be aware of high stress areas and joints of the pep, be sure to lay big or long pieces in these areas.
    f. Check to make sure you got fiberglass on all the interior surface and take a minute to clean up the piece. It is a lot easier to cut the edges of the fiberglass now than it will be once they are hardened.
    g. A problem I've had in the past is that once I douse the piece to soak the fiberglass in resin..the fiberglass starts to move around. The adhesive spray starts to dissolve and I'm left with frustrating situation. Here is my solution to that: I like to sprinkle a little resin into the piece.. like 1oz or less for the piece shown here. Once it hardens it will be like little thumb tacks holding my fiberglass pieces down.
    Let this dry for 1 hour. You will thank me later. :)
    h. Once you are ready go ahead and mix up a lot of resin. 4oz for a medium piece and 8oz for a large piece. Pour the resin in trying to get as much surface area hit by the pouring liquid. Once it starts to pool up then you can take a brush to move it around. The goal is that every single inch of that fiberglass gets soaked in resin. If the resin stops pooling and you still have fiberglass that is dry like cloth then mix up some more resin. You can't have too much here. Every bit you add with just strengthen it.
    Let it dry for 24 hours
    and make sure it is not resting in a way that the resin will seep out and pool or you may have just resined your piece to your table.

    *The resin hardening can create gas fumes. This process may result in bubbles forming under the fiberglass. You do not want bubbles! Take your paint brush and poke these bubbles down before they harden.

    *You can take this opportunity to modify your pieces to your needs. Here I've left support beams that will actually be fiberglassed overtop later creating a pocket for my cell phone.
    Here is another tube I made out of plastic binder material that I will fiberglass to create a place to store and hide my water bottle.

    (once all your stuff dries it is going to cut you when you try to handle it. The next post will be how to make it easier to handle and prep for bondo)
    Last edited: Sep 7, 2017
  2. mblackwell1002


    Good idea for the water bottle hidey-hole. That will be very useful.

    I can't wait to see more Bondo'd progress. It's gonna be awesome.
    PerniciousDuke and PaiganBoi like this.
  3. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer

    Been too long folks! I've been creepin, and building, and creeping some more. But my progress has not really been picture worthy.

    Until... Wait, what's this!?
    All my pieces hardened?! Yup.

    Some of them are in the first phase of Bondo while most are just now ready to be bondo'd. I've also done a few practice visors and I am liking silver with the color pallet. Thinking maybe even white accent lights for the suit.

    Let me know what you think!
  4. SI3RRA 117

    SI3RRA 117

    Looking great looks like a lot of sanding but the end is in sight. I'm digging the silver visor and personally like white lights as well.
    PerniciousDuke and Dirtdives like this.
  5. Dirtdives


    Looks FANTASTIC!!!!! To be honest, it also looks creepy........corps like actually......I used your technique on my son's helmet......adhesive spray and all.... and it came out great. TY so much for posting your method.
  6. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer

    That's great to hear you got some use out of it! I'll try to compile it into it's own thread so it's easier for others to find. Thanks DD.
    Dirtdives likes this.
  7. Schankerz


    GOODNESS ME THE PROGRESS! The duck helmet is looking awesome with silver, keep on quack-a-lackin! :p (it's crack-a-lackin but with quack because duck....I'm sorry...)
    PerniciousDuke and Dirtdives like this.
  8. Dirtdives


    Is there a button I could push to "Dis-like"?
    Schankerz and TurboCharizard like this.
  9. PaiganBoi


    Ha... I guess this adds to your impression of Canadians being a wee bit on the weird side?
  10. Dirtdives


    Just remember.........you said it not me.
  11. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer

    I went to my first comic con, JCCS, and I had a blast! Obviously my suit wasn't ready, but I got to see some fellow 405thers and many other great costumes.

    (picture not working)

    Thom A293

    This was my favorite (non-friend's) costume..

    This was a spur of the moment assembling of amazing panel speakers who were actually just audience members who stepped up when no one showed up to speak! Talk about confidence in cosplay!

    It's me!
    Super stoked for ECCC now!
    Last edited: Nov 5, 2017
  12. Thom A293

    Thom A293

    Fun stuff man! It was great to meet you guys. Also nice progress man, gotta start painting!
  13. Dirtdives


    Wow dude.....you couldn't have picked a better or more appropriate backdrop poster than "Stranger Things" to promote yourself.......Do you watch?
    PerniciousDuke and Schankerz like this.
  14. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer

    :p of course I watch.


    Slow and sweet. This is when my pieces really start to take shape.. Quite literally. As I shape the pieces with Bondo all the divots and sunken or misshapen areas start to smooth out.

    First I've markered off all the surfaces I need to Bondo. A lot of these lines I sanded down too far and broke through to the paper. I went through 10 bottles of super glue to reharden the paper.

    Now I have pieces with no Bondo, some with a half coat and some with a full first coat. I've just been putting a little on a piece and then grabbing another. Hard right now as it's raining. Seriously I've been getting all my supplies out on the balcony once the skies clear up and bonding until it starts raining on me 40 minutes later. #washingtonlife
    Last edited: Nov 13, 2017
  15. mblackwell1002


    No pictures means it didn't happen...until then...i'll just pull a Spartan55.


    Oh yes. Maturity goes out the window. That just happened.
  16. Spartan55


    Oi that's my thing:p
    Also you need to scream it!!!
  17. Dirtdives


    We'll be lucky he knows how to spell it let alone scream it!!..........:p
  18. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer

    I'm glad I have someone keeping me honest. Even if he is a banana, I mean bananas. :whistle:

    Pictures fixed mblackwell1002
    Dirtdives and SI3RRA 117 like this.
  19. Dirtdives


    I don't think "bananas" is the proper word to describe mblackwell1002.....He has his own unique way of seeing things that defies logic.......I think only BW can truly capture what it means to be BW..........I think we need a new Dictionary word. And no...I'm sorry....Genius isn't one of them........well no, not sorry.
    PerniciousDuke likes this.
  20. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer


    My first test fitting!!!

    The arm pieces didn't fit over the undersuit so I have to figure something out. But it was nice to see how they fit together and where I need to make improvements.

    Mostly this weekend will be for Bondo. Everything here should turn red with a first full coat. I like working in alternating colors so that I know if I'm sanding too far.
  21. SI3RRA 117

    SI3RRA 117

    Nice scaling looks pretty dam good. Plus I think it’ll look even better with those fancy height boosting boots. Helmets looks great and I think you’re working magic with that bondo. Can’t wait to see more progress
    Dirtdives and PaiganBoi like this.
  22. mblackwell1002


    Scaling looks so good, man! Looking great!

    You're making great progress! Keep it up!
    Dirtdives and SI3RRA 117 like this.
  23. PerniciousDuke

    PerniciousDuke RXO 405th Regiment Officer

    Thanks guys! I'm already at 9 hours of just Bondo work this weekend and I think I'll be able to get 15 more in before Monday. T-minus 3 months. :confused:
    Dirtdives, Schankerz and SI3RRA 117 like this.
  24. mblackwell1002


    You got this. Don't be Cayde.
    I got this.gif
    I don't know how you do it so fast man, I've sanded my hand cannon for upwards of 15 hours. And that's just one prop! Pffrrrt, you're fast! I need to work faster, lol...
    Last edited: Nov 25, 2017
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  25. Dirtdives


    I think it's because PerniciousDuke uses bondo sparingly.....it makes sanding much easier........It helps when the under-frame is near perfect.....like PD usually does. It will always need only a little bondo.
    PaiganBoi and SI3RRA 117 like this.

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