Emile Suit ( Plastic Coating Foam Technique)

SIKAXIS

Member
Well this is it! I have been planning on doing this build for a while but now that I have started on some of these pieces and I think I can finally post here. Yup I have a lot of big plans for this suit, the main one being molding and casting my helmet. I have watched a TON of tutorials so I am ready to put all my knowledge to the test. I have finished (basically) pepping the helmet. and Have also started on the Kukri. I have a bit of work done on the chest, but I'll get more pics of that when I finish it. I am doing a foam suit, but I was hoping to follow James Burton's ( or is it Bruton?) tutorials and coat the whole thing in some polyurethane to get the hard plastic-like shiny suit that I have always wanted. I picked up some scrap wood from a construction site so I am going to be building a vaccum former from that as well within the next week. Well Enjoy what I got so far!

Also I see a lot of people with tiny images in their posts, is that what everyone does now? or are they just too lazy to upload to photobucket? I personally dont like having to open a link to see the full size image
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The knife blade was surprising easy to make. I bought some base wood at michaels and it was able to cut with just a razor blade. Then I used some sort of gardening tool to sharpen the edge. It isnt too big of an edge,but its there
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Vrogy

Well-Known Member
Re: Emile Suit +Mold & casts

http://en.wikipedia.org/wiki/Kukri

"Its heavy blade enables the user to inflict deep wounds and to cut through muscle and bone. It has been recorded as being able to cleave a person's head and halfway through the chest with a single blow[SUP][citation needed][/SUP]. At the base of the blade is a notch called thecho. Its primary purpose is to serve as a blood drip during combat. The wielder could also extend their forefinger over the cho and flick the blood at their opponent's eyes in a technique called "Vishnu Finger""
 
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SIKAXIS

Member
Re: Emile Suit +Mold & casts

Thanks for the info on the Kukri... I didn't realize it had such a... unique story...
Well I got the resin on the outside of my helmet and last night I was able to finish my first forearm. I had already done some work on it so it was mostly adding the details. I should have the second one done soon too.
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SIKAXIS

Member
Re: Emile Suit +Mold & casts

Get Ready for some pics!
Well It's been rainy these past few days and so I used that as an excuse not to start putting bondo on my helmet.
Does the moisture even affect bondo curing?
I did get some other stuff done and I have a ton of pictures
My helmet is now completely hardened and ready for Bondo
I finished my other forearm. I did some of the details a bit differently though.
I finished the Kukri and the Sheath. I used aluminum foil to get the shiny edge on the knife. It's not exactly what I was looking for, but it will do for now.
I also started on the grenades for the belt. I figured I would just mold and cast one of them since it would be a pain to do all 10.

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I think I may have overdone the weathering on the sheath, but it still looks hella tight.
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SIKAXIS

Member
Re: Emile Suit +Mold & casts

So Yeah, I haven't updated this thread for like 2 weeks, but I am still hard at work on my armor. I just finished the hardest piece ( well the helmet's not done...) so the SECOND hardest piece
Chest piece complete. I actually started on another one earlier and it was too big on me. this one is pretty snug now, but it looks a lot more accurate than the last. I can't get my head in with the collars so they are not hot glued on there completely, they're just hanging on by like a hinge which I can flip up once my head is through. I have been trying to work on my helmet and I think I have the visor as smooth as it's gonna get. I feel like I can't get it any more round. If you guys have any tips for getting perfectly rounded surfaces they would be much appreciated. i also fixed the side vents to make them more game accurate. I just used some bondo and plastic strips to get them flat and the edges straight. I am glad how they're coming along. Today I won't be working more on the helmet since it's raining, but I will try and get as much done as I can before the weekend.

Oh and before I forget, I tried using the silicone caulk method to make a mold for my grenades, but there were so many tiny airpockets that formed that it ended up leaving bumps in my first cast. I guess I will have to get some of the expensive stuff If I want it done right.
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FoxtrotZero

Jr Member
Re: Emile Suit +Mold & casts

I like how this is coming along so far. I look forard to seeing the vacuum forming process, because I actually don't know very much about it.

I'm currently doing an ODST build but the more I think about it, the more I'm interested in making a foam SPARTAN from Reach, so I should start paying attention to builds like yours.

Anyway, it's looking really good, so keep it up and keep us posted!
 

SIKAXIS

Member
No kidding, I thought this thread would've been lost forever by now... Yeah so I haven't posted in... A long time... but I'm still working on my emile suit. I Also changed the name of this thread because I am no longer planning on making casts of this helmet. After the trouble I had vacuum forming I couldn't imagine trying to make a whole bunch of these. Like the new thread title says I am planning on coating the whole suit in Smooth cast to reinforce it. I have tested it on one of the biceps and it seems to work pretty well, but I will need some more brushes before I can coat all of them.

Since I last posted this is what I've done. 1. Finished one bicep 2. Finished security shoulder 3. started on shins (nearly finished) 4. coated some pieces in PVA (white glue) 5. coated bicep in Smooth on. 6. Cut Visor out of helmet 7. finished most details on helmet although I'd rather not show it in its current state

After coating the bicep with smooth on it looked a bit patchy, but once I hit it with some primer it actually looked pretty good.
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1stSGT N161

New Member
Sub'd to the thread. Can't wait for updates. Just keep up with the excellent work, take it slow, enjoy the process and this will be a a fine kit.

Nice to see another late Spartan I I I build. Emile is pretty bamf
 
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