James Jordan

A quick update, managed to cast the helmet not a brilliant...

Sun, 16 Dec 2012 20:43:19 +0000

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.

Photo

Sun, 09 Dec 2012 22:35:32 +0000

first half of the helmet mould complete, just need to fill in the gap between the silicone and the plaster bandages with some silicone so i get 2 perfect halves

filling in the small channel left by the clay wall, this is so i get 2 halves which fit just right

just a quick alignment of the chest and my old chest piece bit rough still, the back piece where it joins by the ribs doesn't quite match up right, the back is a bit higher than the chest

cut out the ribs as they were a bit messy and hard to get at with sandpaper so ill do new inserts

Silicone moulding of the helmet part 2

Sun, 02 Dec 2012 23:05:15 +0000

Silicone moulding of the helmet part 2

Silicone moulding of the helmet part 1 Basically started to...

Sun, 02 Dec 2012 22:27:44 +0000

first really thin layer of silicone rvt to capture the detail

plaster of paris bandages for the rigid mother mould vital for holding silicone mould in shape when casting

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.

Photo

Sun, 25 Nov 2012 23:27:21 +0000

second rondo coat on both sides much more rigid now

Exploring new coating process using Rondo a combination of car...

Sun, 25 Nov 2012 23:12:52 +0000

first coat of rondo needs coating on the inside for better strength

second coat of rondo much stronger and less flex

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...

Tue, 20 Nov 2012 22:31:00 +0000

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...

Tue, 20 Nov 2012 22:23:21 +0000

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...

Sun, 18 Nov 2012 23:54:26 +0000

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...

Sun, 18 Nov 2012 23:46:49 +0000

The biceps and some more images

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

More sanding and stuff… The shoulders are almost done...

Sun, 18 Nov 2012 23:27:05 +0000

More sanding and stuff…

The shoulders are almost done just a few touch ups to do also going to get the round areas/bolts cnc cut again like I did with the helmet ears.

Done some more sanding and filling on the helmet again, managed to get the chance to use my rotary engraver on the ears took no time at all to do almost cut back to foam underneath. There’s still a few small details to do but it’s quite difficult to get to them so I’ll prob glue on the ears and fill any small bits I’ve missed with clay that I’ve got for silicone moulding. Talking of which if all goes well I should be able to start next weekend if the weather stays good.

Erm what else….the chest is 90 percent started to file down the lines where the joins are in the armour and did some work on the ribs the small gaps on either side it’s really difficult to get at so I might cutout those sections completely and do nice new inserts.

Also got at the biceps which I wasn’t planning on doing till next week again there’s just some filling to do with body filler on the flat sections which close up you will in the next post.

Finally did a really quick rough sand down on the ribs which doesn’t look to bad some more filler and getting in those gaps which is a right bugger to get at.

To be continued…

More sanding and stuff… The shoulders are almost done...

Sun, 18 Nov 2012 23:21:43 +0000

More sanding and stuff…

The shoulders are almost done just a few touch ups to do also going to get the round areas/bolts cnc cut again like I did with the helmet ears.

Also got at the biceps which I wasn’t planning on doing till next week again there’s just some filling to do with body filler on the flat sections which close up you will in the next post.

Finally did a really quick rough sand down on the ribs which doesn’t look to bad some more filler and getting in those gaps which is a right bugger to get at.

To be continued…

More sanding and stuff… The shoulders are almost done...

Sun, 18 Nov 2012 23:20:02 +0000

More sanding and stuff…

The shoulders are almost done just a few touch ups to do also going to get the round areas/bolts cnc cut again like I did with the helmet ears.

Also got at the biceps which I wasn’t planning on doing till next week again there’s just some filling to do with body filler on the flat sections which close up you will in the next post.

Finally did a really quick rough sand down on the ribs which doesn’t look to bad some more filler and getting in those gaps which is a right bugger to get at.

To be continued…

Photo

Sun, 18 Nov 2012 23:19:31 +0000

More sanding and stuff… The shoulders are almost done...

Sun, 18 Nov 2012 23:19:22 +0000

More sanding and stuff…

The shoulders are almost done just a few touch ups to do also going to get the round areas/bolts cnc cut again like I did with the helmet ears.

Also got at the biceps which I wasn’t planning on doing till next week again there’s just some filling to do with body filler on the flat sections which close up you will in the next post.

Finally did a really quick rough sand down on the ribs which doesn’t look to bad some more filler and getting in those gaps which is a right bugger to get at.

To be continued…

Photo

Sun, 18 Nov 2012 23:18:50 +0000

The chest piece almost done, nice and smoooooth just going over...

Mon, 12 Nov 2012 21:57:04 +0000

The chest piece almost done, nice and smoooooth just going over the details with filler as bits of the detailing started to crack off, but almost there.

Started on the back piece, although….thinking I might use my old back piece from the cardboard build a few months ago as its pretty much done already and all it needs is some adjusting with a hot air gun to align up with the new chest…shall have a play…

slow progress tho..stay tuned

Progress part deux Following on the helmet has had second layer...

Sun, 04 Nov 2012 22:04:57 +0000

really cool gun attachment for the spray paint can so handy in the cold weather

The chest is nice and smooth now, looking closely I've attempted to file lines that show the joins in the armour around the arc region

Biceps will need some filling and work with the engraving tool but looking good

Progress part deux

Following on the helmet has had second layer of primer, looking really smooth now, still few details that need doing which will require a tiny bit of filler and a engraving tool to capture those small details. Then it’ll be ready for moulding.

The chest also primed is mostly smoothed out now, just the edges need rubbing down and needs an engraving tool for the smaller details.

Primed one of the biceps needs some body filling and the engraving tool for the defining the lines.

Slow steady progress helmet should be finished soon, then the chest and arms.

Having a re-think about the back piece, wondering whether to incorporate the gun pods that pop out and the missles that jump out…will sketch it out

Progress 1 of 2 Been working on the helmet during the week...

Sun, 04 Nov 2012 21:48:01 +0000

First coat of grey primer, really useful for spotting areas that need further sanding and filling

Some body filling after the first coat of primer noticed some small holes in the plastic coating most probably bubbles in the resin

Again more filling this time on the chest piece

Did a test fit of the thigh and shin on the right leg, was tight fit especially round the knee, will have to use a hot air gun or hair dryer to bend/flare out the joint area on the thigh

Progress 1 of 2

Been working on the helmet during the week sanding it down, then applying the first coat of primer so all the little rough and uneven spots show up clearly, which grey primer is great at doing. Then, used car body filler to patch up those spots followed by further sanding down. The second coat of primer will be in the second update.

I’ve also done the same to the chest piece and this will be done to the biceps/shoulders over the next week or so.

to be continued…

Update: Been focusing on the helmet this weekend and wrist cover...

Sun, 28 Oct 2012 21:11:23 +0000

Wrist cover, this will be my test dummy for silicone moulding

Update:

Been focusing on the helmet this weekend and wrist cover for silicone moulding which if all goes right I can make many more iron man helmets :-D

Helmet needs more sanding and filling, but shouldn’t be much longer, really pleased with how its looking the pictures don’t it justice tbh once i’ve got some grey primer on it and some of the details sanded in I’ll put more photos up and hopefully it should be ready to be moulded.