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Disturbingly I came across a few air pockets inside the cast that I've had to fill. Initially after picking off the thin plastic skin covering them, I found they tend to be larger inside the cast then first appeared on the surface. I found a major pocket towards the edge of the mohawk which you can blatantly see, but I have now filled these out and sanded them down.

A series of smaller air pockets to the side now filled and also ive circled the flakey bottom edge to the helmet which had chipped slightly where once again the cast thinned out too much. I've now also filled that edge inside and out to give the helmet a very solid smooth finish.


And last but not least, I've now sanded the re-inforcer filler inside the helmet to a smoother finish. I'm not too bothered about getting that flush as it won't be seen and once I've spray painted the inside and further down the line, added various padding etc, it hopefully shouldn't notice. Again you can see ive filled out some of the bottom edges inside and out where needed.

I guess to some you might be thinking where the hell did he pick up such a problematic cast?
Well this is part of the course for the rarer whole helmet cast it would seem. It certainly has been time consuming, just when you think it's taken as much filler as it needs, there is always some other imperfection waiting to be discovered. I really think I've conquered it's surface terrain now though, so in the next couple of days I'm hoping to give it the first coat of primer.

It is looking very good. Too bad about the extra work on the air pockets. Little fill, and elbow grease and good to go.

Primer filler sprayed and Eye Holes put in today, this holes were a little more difficult then I'd hoped. May need re-pinning in due course.



Suspense support glued inside today, this is a plastic garden cane connector you might find in a Runner Bean or grape vine structure if you into your gardening. The cane will fit inside this and will support the helmet free from any surfaces whilst I give it another layer of Primer and also hopfully will hold up for the Chroming process.



Sanded again ready for the final layer of Primer which, weather permitting I will spray on tomorrow.



My new order arrived today courtesy of Hand-Schaub, looking forward to working on this once the helmet is all but chromed, hopfully this weekend.

So you've got all the parts to make your dream come true!

Good luck with it.

Been getting on with the build over the last fortnight.

Ok Mouth Grill required some attention, this is a resin peice as is the visor. Both are quite light in weight but also pretty delicate, one drop or a mishandle and bits will chip off quite easily.



The Visor needed the lense cutting out, which i chipped away using my modeling scaple knife.



After a decent amount of resin chipped away I sanded to a smooth finish.



Right, Helmet pretty much finished now before chroming so time to move on to the armour stuff.

Power Pack

This is one of the hardest things I've tried to build so far so bear with me if my technique seems rather unnorthodox or amateur.

I tried initially using some pastic bonding glue but that turned out to be a disaster and gave me sticky hands for a whole weekend after I went a bit mental trying to hold the thing in place while it set (try explaining that one the the good lady). It didn't set quite how the instructions predicted and after some initial disbelief I conceded that the Bonding had for all it's promise, actually managed to stick bugger all.

Back to the drawing board. I next dug out some good old "No Nails" glue I had leftover from some home interior decorating last year. Preferably used for wood but after the dissapointment of the uselss bonding, I was willing to give it a go.

First arm attached, drying.




24 Hours later, second arm attached, drying.



48 Hours later, Power Pack casing glued into position.


Note the use of Cellotape to clamp the casing to the arms as best I could, looks hideous hey?

Drying


Is going to require a lot of filler round the arms to seal them to the casing and to generally smooth off the edges. I'm confident using the same filler I used on the helmet, I'll get it to a good finish before priming. Hoping to get this up to standard this weekend. The No Nails has done a wonderful job, the Power Pack feels solid enough to handle without risk of a rupture and I'm hoping once filled, it will be very sturdy. I have tried it on and it actully fits and sits like a dream. High hopes...

In the meantime I've started on the Bicep Rings with once again, No Nails and held in place by good old fashoned clothes pegs...


More to follow weekend.

AMAZING! Great work! Love the update.

cool - nice update. Tomorrow I send out your sword!

Yeah the back pack is a tricky build. A professional builder that built a Studio Scale Galactica got a hold of me once to find out how to build the darn thing after he took it apart. Man the crazy design on this piece. Awesome if you think about the overall design. Everything is looking great.

Great work so far indeed!

Stupid Video to keep me entertained...



Hope you don't mind me using your logo's.

Nice work!

Very cool video. I like it, and no problem using the logo.

ross0379 wrote:Stupid Video to keep me entertained...
Hope you don't mind me using your logo's.

I love it! So creative.
If you'd like any image for a future video, just let me know.

Okay enjoying the freakish hot weather here in the UK the last week, so been outside doing some things.

First up the power pack has come along nicely.

Filled in the gaps usig Car Body filler again, used shed load of this suff now.




This stuff goes solid in under 8 minutes once the padding is added, so it really is a race agianst time to slap it on, hence why it's not quite the smoothest of appliance one should be making.

Sanded down for the 4th and final time





Although not captured quite so clearly on my camera phone, my finish using decending grades of sanding has given it a good smooth final result. Just need to apply that first coat of primer to it now for which I have 5 cans of spray on order.

The power pack is going to be an all in one piece with no detachable parts. Here's me modelling it

And from the back


Time to crack on witht he other pieces...

First up Belt Boxes


Second up, Shoulder Bells and Scallops


Third up, Guantlets left and right

Filled and half sanded



Fourth up, Chest Bar.... Note ingenius use of a makeshift weight to hold the pieces in place whilst it glues...


Works in progress

And finally for now, here the chest bar alongside my new Cylon Centurion sword courtesey of Mr Hand-Schaub. This magnificent piece arrived the weekend and looks and feels great. I'll have to be careful not to wield that in public cos it looks pretty dangerous from a distance.