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A quick update, managed to cast the helmet not a brilliant mould there’s some bubbles that have formed and popped in the first cast leaving some lumps which are in the pictures and they will need filling in.

overall fairly happy I think I will do another mould in the new year when the weather is better I think I rushed this one and moulding in the dark was a silly idea.

Probably be my last update for a while xmas cold weather excessive drinking etc so look out for updates in the spring might build the mark 7 from the avengers or the mark 3 not sure but I might just do a foam suit which ill spray not coat it in plastic just as a suit for better movement and something I can wear out for fun.

Silicone moulding of the helmet part 2

Silicone moulding of the helmet part 1

Basically started to make a mould of the helmet so I can replicate the original and produce many more iron soldiers lol.

It’s a long winded process but worth it if you do it right as I said once it’s finished I can pour liquid plastic into the mould and make many more.

To start off with you need to divide the helmet by using a blank or board which needs a section cutting away so the helmet slides into the gap, then using clay build up a wall or barrier so one half of the helmet is sealed.

Then create a keyed edge, so make holes so when you do the other side it locks into place as a reference point so when you take it apart and put it back together you always have those points to locate the two halves back into the correct position again.

Think of the clay wall as a moat or channel so when you pour the silicone in it the wall stops it dripping everywhere.

Then a thin coat of silicone, followed by 2/3 thick coats and using a ice cube rack make cubes as key points for the rigid mother mould to lock to. Basically following the xrobots.co.uk method.

Still waiting the plaster bandages to dry which is worrying as it still damp after a day and I really want to get fibreglass on top to make it stronger then I can do the other side.

Long and boring but hopefully get it done for next weekend.

Not much else really as it’s getting colder finding it harder to stay outside longer, but some pics in part 2.

Slow and steady wins the race as a friend once said.

Exploring new coating process using Rondo a combination of car body filler and fibreglass resin mixed 50/50.

This method came from looking at the rpf forum and I found a dicussion where someone had invented a new coating process so I tried it out on the hand cover, which I had ready, all it needed was a coat of pva glue on top to help the rondo mixture stick to piece.

It’s easy to sand and I’ve put on the second coat which hopefully after sanding down will be smooth and ready for spray, this is a much quicker method than the plastic resin I’ve been applying and cheaper to. The rondo is really good because it has the thickness of filler and the smoothness of the resin, combined together only takes 20 mins to go off.

Another advantage is there’s no flakey or bubbly bits when it reacts and drys on the piece.

Not much else really helmet is almost ready got the ears on and used clay to patch up odd spots and then onwards to silicone casting got the split divider so I can make it in 2 pieces for easy release.

Ribs and forearms have been sanded down needs more filler etc.

And the rest, rough quick (lol) sand on one of the forearm’s and a primer coat.

Nice new elbow piece ready for plastic coating.

Quick layout of the foam pieces stuck together then cardboard stuck on top for a cleaner finish.

Some more images off my phone of the biceps just after sanding and just before spraying.

Sawn off the elbows which I’m going to rebuild as a separate piece as it’s much cleaner to do it this way and also removing the elbow covers gives me room get inside the forearm and apply plastic resin so the forearms are solid inside and out.

The biceps and some more images


Will start on the forearms next week going to saw off the elbows then re-align them as one has stuck to the forearm section. Hopefully shouldn’t be to much work as the the plastic resin is nice and smooth and rigid so it’s quite strong now and little bit of sanding where there’s bubbles and drips should do the job.

Will work on articulating the arms when that’s done and hopefully be able to wear them.

The biceps and some more images


Will start on the forearms next week going to saw off the elbows then re-align them as one has stuck to the forearm section. Hopefully shouldn’t be to much work as the the plastic resin is nice and smooth and rigid so it’s quite strong now and little bit of sanding where there’s bubbles and drips should do the job.

Will work on articulating the arms when that’s done and hopefully be able to wear them.

A quick update, managed to cast the helmet not a brilliant mould there’s some bubbles that have formed and popped in the first cast leaving some lumps which are in the pictures and they will need filling in.

overall fairly happy I think I will do another mould in the new year when the weather is better I think I rushed this one and moulding in the dark was a silly idea.

Probably be my last update for a while xmas cold weather excessive drinking etc so look out for updates in the spring might build the mark 7 from the avengers or the mark 3 not sure but I might just do a foam suit which ill spray not coat it in plastic just as a suit for better movement and something I can wear out for fun.

Silicone moulding of the helmet part 2

Silicone moulding of the helmet part 1

Basically started to make a mould of the helmet so I can replicate the original and produce many more iron soldiers lol.

It’s a long winded process but worth it if you do it right as I said once it’s finished I can pour liquid plastic into the mould and make many more.

To start off with you need to divide the helmet by using a blank or board which needs a section cutting away so the helmet slides into the gap, then using clay build up a wall or barrier so one half of the helmet is sealed.

Then create a keyed edge, so make holes so when you do the other side it locks into place as a reference point so when you take it apart and put it back together you always have those points to locate the two halves back into the correct position again.

Think of the clay wall as a moat or channel so when you pour the silicone in it the wall stops it dripping everywhere.

Then a thin coat of silicone, followed by 2/3 thick coats and using a ice cube rack make cubes as key points for the rigid mother mould to lock to. Basically following the xrobots.co.uk method.

Still waiting the plaster bandages to dry which is worrying as it still damp after a day and I really want to get fibreglass on top to make it stronger then I can do the other side.

Long and boring but hopefully get it done for next weekend.

Not much else really as it’s getting colder finding it harder to stay outside longer, but some pics in part 2.

Slow and steady wins the race as a friend once said.

Exploring new coating process using Rondo a combination of car body filler and fibreglass resin mixed 50/50.

This method came from looking at the rpf forum and I found a dicussion where someone had invented a new coating process so I tried it out on the hand cover, which I had ready, all it needed was a coat of pva glue on top to help the rondo mixture stick to piece.

It’s easy to sand and I’ve put on the second coat which hopefully after sanding down will be smooth and ready for spray, this is a much quicker method than the plastic resin I’ve been applying and cheaper to. The rondo is really good because it has the thickness of filler and the smoothness of the resin, combined together only takes 20 mins to go off.

Another advantage is there’s no flakey or bubbly bits when it reacts and drys on the piece.

Not much else really helmet is almost ready got the ears on and used clay to patch up odd spots and then onwards to silicone casting got the split divider so I can make it in 2 pieces for easy release.

Ribs and forearms have been sanded down needs more filler etc.

And the rest, rough quick (lol) sand on one of the forearm’s and a primer coat.

Nice new elbow piece ready for plastic coating.

Quick layout of the foam pieces stuck together then cardboard stuck on top for a cleaner finish.

Some more images off my phone of the biceps just after sanding and just before spraying.

Sawn off the elbows which I’m going to rebuild as a separate piece as it’s much cleaner to do it this way and also removing the elbow covers gives me room get inside the forearm and apply plastic resin so the forearms are solid inside and out.

The biceps and some more images


Will start on the forearms next week going to saw off the elbows then re-align them as one has stuck to the forearm section. Hopefully shouldn’t be to much work as the the plastic resin is nice and smooth and rigid so it’s quite strong now and little bit of sanding where there’s bubbles and drips should do the job.

Will work on articulating the arms when that’s done and hopefully be able to wear them.

The biceps and some more images


Will start on the forearms next week going to saw off the elbows then re-align them as one has stuck to the forearm section. Hopefully shouldn’t be to much work as the the plastic resin is nice and smooth and rigid so it’s quite strong now and little bit of sanding where there’s bubbles and drips should do the job.

Will work on articulating the arms when that’s done and hopefully be able to wear them.

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