ODST Foam build - Stepping up from DFT (Finished Build Pic on Pg. #8 & 9)

Elcorio

Member
Not much progress thus far. Boot covers are giving some issues and I don't quite like the way they are coming out, so back to the drawing board.

Cast a skull and cut out the flames in foam. Thinking I might add it to the center chest piece. Teeth or no teeth? Of course they will need some more work with paint, etc.
20180914_194735.jpg 20180914_194759.jpg
 

Elcorio

Member
Alright there folks, 2nd forearm is complete, butt plate and cod piece are done! Last stop is the helmet. Actual build is nearing the end, then its on to filling in small gaps, smoothing out hard lines, then seal and paint! Nylon webbing and elastic webbing is on order for strapping it all together. Still have a bit to go, but slowly and surely, it'll get there.
20180915_084204.jpg 20180915_084208.jpg 20180915_084440.jpg 20180915_133844.jpg 20180915_134226.jpg 20180915_134232.jpg 20180915_215741.jpg
 

Elcorio

Member
By filling in small gaps do you mean just straight to painting? As those are some snug lines, yo! Great work!
Thanks. I want to knock down some of the hard seam lines and fill in a few small areas were the foam pieces might not have closed completely or had gaps.

I've also have never been to a con and today our local library held a small one. Suited up my youngest in his DFT armor. Had a blast and going to start planning for the bigger one in New Orleans next year.
20180923_141055.jpg 20180923_142608(0).jpg 20180923_144122.jpg
 
Last edited:

Elcorio

Member
Started sealing the foam using Mod Podge. Shooting for 9-10 total coats per piece. These are at 5-6 coats. Between every two coats of Mod Podge, I lightly sand the edges which is resulting in baby butt smooth seam lines. Then it will be wet sanding with 400 grit wet/dry sandpaper over the whole piece before primer and paint go on. Hopefully, when done, the seam lines will be little more than distant memories. Also order 3 more full sheets (48" X 72") of the XLPE foam in 3/8" and 1/4". That is out for delivery today and will give me enough to build anything else for a very long time and to work on the ODST helmet counting mess ups. AND finally, started working on the inner portions of the thighs pieces. Sizing was a bit off as each piece needs to be slightly longer than the one below it, so it will be back to the drawing board, but I need to get some more 5mm foam. The inner pieces were done freehand, but I need to adjust the sizing for the three pieces in a step up type pattern.

20180929_101059.jpg 20180929_101229.jpg
 

Elcorio

Member
Trying to seal so many pieces all at once became a daunting task, so I decided to just work on one piece from start to finish. Also bought a beginners airbrush kit and thought I'd give the whole airbrushing thing a go.

Pretty pleased with the results so far.
20181014_161519.jpg 20181014_173552.jpg 20181014_180455.jpg 20181014_182031.jpg 20181014_182041.jpg
 
Last edited:

Dirtdives

RXO & Keeper of Con Lists
405th Regiment Officer
Community Staff
That chest piece is amazing!!!!! I may be good at etching in foam but that is a true emblem......I have to try your method out!!!
 

Elcorio

Member
How did you get the square texture in the paint? That looks awesome!
If you look in the background of the picture, you can see apiece of the material I used. It is nothing more than the non-stick, rubber type shelf protector stuff you can pick up for a couple of dollars in the household goods section at Wal-Mart or the like. I botched it up quite a bit on this piece, but was going for a carbon fiber type skin. However, this was literally the first time I have ever used an airbrush. I keep looking at the piece and on the fence of pulling the emblem off, repainting the piece, and trying again.

for an update on the build, the shoulder pieces and butt plate are sealed and need to be wet sanded and then paint. Those will be the next items up for paint.

As a side note: Thanks for all the input guys and gals!
 

Elcorio

Member
its so clean!!!
whats your secret?
Thank you. It's nothing more than repeated coats of mod podge then wet sanding the first couple of layers to smoothness. Of course, it all starts with your cuts, bevels, and making sure the two pieces line up as perfect as possible to avoid any gaps or open seam lines.

I weathered up one of the shoulder pieces and am kind of "meh" to it. In all the excitement of using an airbrush, I forgot to lay down a silver base coat with a barrier for creating a chipped paint look in certain areas.

Unfortunately, I have run into a major fit issue with the forearms and a fit assumption of the thigh and shin pieces. The BDU's I had planned to wear underneath are a bit loose and are not snug to the body. This creates "extra" material that was not accounted for in the sizing. Thus, theses pieces basically do not fit while wearing the BDU's. It was a bit of a bummer and initially destroyed my motivation to keep working on it. So I hung up the build for a couple of days to figure out the next step. I had considered starting all over, but that is a LOT of wasted time and effort. So I think I will look at each piece and see if I can created a clean slice on the underside down the entire length and insert a 3/4" - 1" piece of foam to allow for the added material of the BDU's. I think I am rushing it too much between the sizing and painting and need to slow it down a bit. I'll update as I make on the fly adjustments.
20181021_220049.jpg 20181021_220110.jpg 20181021_220121.jpg 20181021_220150.jpg 20181021_220212.jpg 20181021_220235.jpg 20181021_220241.jpg
 

Elcorio

Member
As mentioned in an earlier post, I really didn't care for the botched carbon fiber effect and the ad hoc ODST emblem on the chest plate that was noobishly thrown on to quickly. Sooooo.........it all came off, sanded down, and a new coat of primer was applied.
20181025_191528.jpg

From there, a barrier (AKA: Vaseline) was added and then hit with a silver paint. The idea was to give the piece some depth between the gray primer and the silver.
20181025_213624.jpg 20181025_213619.jpg 20181025_213612.jpg

More Vaseline, then the straight black and blue were applied. A little bit of metallic saphire blue and sequin black dry brushing followed by some umber brown in the crevices to "dirty it up", then to a straight black wash to mute the silver and gray colors down a bit. That was then followed up with a umber brown wash to enhance the grime and wear and tear of battle. Lastly, a metallic gunmetal around the edging to highlight wear edges. I still am not comfortable with cutting or puncturing the piece to create an impacted look, but will practice that on some scraps first.

I opted to not put the emblem back on the chest plate and am now looking into just creating an ODST stencil with cardstock, then airbrushing the emblem on. IMO, this seems like it would be better served on battle gear versus some big protruding emblem on the chest plate.

Now I am finally happy with the way the paint scheme is coming along. Next up will be sealing, sanding, smoothing, and painting up the thigh and shin pieces. As a side note, the helmet is a dismal mess. After repeated tries with foam, I just cannot seem to master this and have opted to just save the foam (and money) and buy one from a reputable source.
 
Last edited:

kyle clement

New Member
Hey Elcorio how did you attach the quick release buckle to the foam? I am looking to do the same and I was going to magnet my shins but the one I tried today didn't come out very good so I am thinking about putting the buckles on them as well
 

Elcorio

Member
Hey Elcorio how did you attach the quick release buckle to the foam? I am looking to do the same and I was going to magnet my shins but the one I tried today didn't come out very good so I am thinking about putting the buckles on them as well
I think I have some pics of when I was building them into the foam. Essentially, I placed the buckle on the foam (1/2" foam), traced an outline, cut as much as I could with a blade, then dremeled the rest. Used contact cement to mount the buckle into the cavity I made in the foam then reinforced it with popsicle sticks on the interior of the foam piece. From there, I just covered it all with some 3mm foam for aesthetic purposes. I ended up cutting slits in the foam and use popsicles sticks hot glued in place to act as guides for the remainder of the pieces to be joined.

I'll see if I can find the actual pics as I was building it and post them.
 

kyle clement

New Member
Thank you elcorio. That is the part I was trying to make sure of was if it was attached to strapping or straight to form. I'm looking at going the same route and my attempt at magnets on my shin piece didn't come out very well so I may try these latches on the shin as well
 

Elcorio

Member
Thank you elcorio. That is the part I was trying to make sure of was if it was attached to strapping or straight to form. I'm looking at going the same route and my attempt at magnets on my shin piece didn't come out very well so I may try these latches on the shin as well
Just to add a bit of build tips to the buckles. I also added a short piece of 3/4" nylon webbing folded in half where the strap would have gone for a helmet for added strength. Contact cement was used to secure it all and when I decided to go another route on the build, I literally had to cut everything out because the foam would tear if I tried to pull the buckles off.

What kind of magnets are you using? The ones I used in the forearm are neodynium bar magnets and even using their small edge, they have unbelievable holding strength. I believe somewhere in the 33 Lb. area. If using the flat broad side, I believe the foam would rip before the magnets would give. In fact, the magnets come with a small plastic separator between them because you have to slide them apart. There is no way you can simply pull them apart. You have to slide them away from each other. If you are using the cheaper ceramic magnets, then yeah, I could see the lack of holding power.
 
Top