My Carter Commando armor

[ErMaC]

I should be done with the helmet in a few short weeks. I have updated pics to upload later on today. I am turning this helmet into a mold. It's taking me extra time to make sure I have all of the seams, edges and surfaces even and smooth. I will be using smooth on products to make the mould. But don't worry I am definitely casting this helmet. And thank you for viewing.

 

[RobTC]

Oh, ok, I was getting confused with the adding of the visor and wearing it, rather than sculpting a visor placeholder and stuff. Looking forward to seeing that, sounds like we'll be moulding around the same time.

 

[ErMaC]

I saw blackula727 mould his helmet with the iridium visor in place. So I assumed that it's not a problem. Let me know if I'm wrong so I can think of something

 

[RobTC]

Honestly I have no idea. Whenever I do helmets, I won't be adding the visor first, mainly just because I don't use masters as useable objects (I'd have filled the interior with foam or something for easy mounting/sculpting/brushing) and I'm planning on vacuforming custom visors to fit anyway.

But that's not to say it can't be done, I just haven't seen it done that way before- I never saw Blackula mould his. If you've seen it work, then why not? Your placeholder will be exactly the right shape and size for the visors you'll be using, so it kinda makes sense.

 

[ErMaC]

I also was going for the thick trim around the visor. And yes, the trim will perfectly fit that visor, I have plans on cutting this visor and use a double visor. I shopped around for a vacuformed Carter visor but I coudn't find one. I'm a beginner and im experimenting a little bit. I'm just hoping I don't mess up. Thank you for your input. Your expert advice truly helps

 

[ErMaC]

I've built out the bottom of the sun visor using epoxy putty ad bondo. I started by figuring out what type of design I wanted to have. I only needed to cut out one piece. I figured I would get the rest of the deign as I went along. Next is forming the epoxy putty to the desired shape around the design in which the detail will be. After obtaining the proper shape and thickness, it was time to divide the sections up as even as possible. I used water and popsicle sticks to shape and smooth out the epoxy putty. After the epoxy putty is dry and cured I layered on 2 thick layers of bondo throughout the entire surface area. As the bondo is starting to cure I used a popsicle stick and carve the edges and corners and clear the area from bondo that I will not be needing bondo. I sanded the area until the surface was semi smooth. I used a large file to make the entire surface as smooth as level as possible. Some additional sanding was needed after filing. After the shape of the area was to my satisfaction, I used a small flat file to test out the line pattern to truly separate the section. When I successful aligned the lines I tested half to see if it visually was pleasing. I used a thick 80 grit sandpaper. I folded the sandpaper in half and started to sand the lines I made with the small file set. After I sanded out the lines I used a 180 grit sand paper and smoothed all surfaces. I still have to use bondo glazing putty to fill in all o f the imperfections. I believe it turned out very well.

 

[ErMaC]

If there are any staff members with the ability to delete threads will you please pm me. I have a few questions to ask. Thank you

 

[RobTC]

I also was going for the thick trim around the visor. And yes, the trim will perfectly fit that visor, I have plans on cutting this visor and use a double visor. I shopped around for a vacuformed Carter visor but I coudn't find one. I'm a beginner and im experimenting a little bit. I'm just hoping I don't mess up. Thank you for your input. Your expert advice truly helps

Sounds like you have a reasonable plan put together! I'm the same, silicone is expensive and scary, at least for the time being.

Ha! The only thing I'm anywhere near approaching expert is visual/spatial problem solving. Everything else I pick up as I go... Though the sentiment is appreciated.

Looks like you have a pretty good Bondo workflow going too, seems similar to mine- I just posted mine in the other thread, haha. It's nice to use as long as you're not impatient with it.

 

[jamestfox]

That helmet is looking great!

 

[ErMaC]

The front area has been a challenge so far. Trying to align it is a challenge on its own. But with a little patients I will manage to get the job done. I use the same process with every section. So all you have to do is read the process below.

 

[ErMaC]

I put a coat of filler paint to expose the imperfections. There are a lot of small imperfection but easy to touch up.

 

[RobTC]

Still a way to go on the chin, but looks like it's coming along nicely, overall!

 

[ErMaC]

Thank you RobTC, Its taking along time but its worth it. I'm just amazed that im doing that kind of work.

 

[ErMaC]

I got the interior and exterior of the thighs, sins, biceps and forearms coated with resin. I'm going to let these cure for a week then it would be time to proceed.

 

[Mstruvmgc]

Everything is looking great!

 

[SuprWeenieHutJr]

You said that you're letting the resin cure for a week, is it necessary to let it cure that long?

 

[ErMaC]

You said that you're letting the resin cure for a week, is it necessary to let it cure that long?

No, it only takes a day or less, I'm just a patient guy, so I let it sit for a week before I touch it again. but you only need to let t dry for a day.

 

[RobertsonCospla]

Awesome work!

 

[ErMaC]

I decided to smother the surface of the jetpack with dura rock dry wall mud just to smooth out the surfaces. I will sand it and decide to go from there. I do plan on spraying Great Stuff (expanding foam that dries very hard) inside the pack as a replacement for rondo. There are to many open openings to use rondo.

 

[ErMaC]

It was a nice day outside today so I got the remaining parts of the armor resined inside and out. The boots only have a coat on the exterior because I am going to use fiberglass cloth on the interior. I need the extra durability. I'm also helping my friend build Iron Man Heartbreaker armor.