My son's halloween costume
 

Now that my armor is done, I have used halloween as an excuse to make luke his. He picked a mandalorian armor as his kit. So i got started.

Been working on the helmet for the last month or so. Started using a pepakura file. I used cardstock as my medium, cut it and glued it together.

http://i307.photobucket.com/albums/n...psxzgd3bhb.jpg

After I got it where i wanted it, I put resin on the outside and fiberglassed the inside.

http://i307.photobucket.com/albums/n...psnilnjtqh.jpg

Once that dried, I bondo'd the outside and sanded it smooth.

http://i307.photobucket.com/albums/n...psrqccy95g.jpg
http://i307.photobucket.com/albums/n...pso1ulla0i.jpg

Re: My son's halloween costume
 

once that was done, I put a coat of primer on it just to make it look better

http://i307.photobucket.com/albums/n...psife0d95i.jpg

Then it was time to make the mold. I went the cheaper route and just used silicone from Home depot.

http://i307.photobucket.com/albums/n...psmgp5huyc.jpg

Then it was time for the mother shell. Made from fiber glass.

http://i307.photobucket.com/albums/n...psiytxb1yh.jpg
http://i307.photobucket.com/albums/n...psih4eqspe.jpg
http://i307.photobucket.com/albums/n...psxjk1dnzt.jpg

Re: My son's halloween costume
 

when the mothershell dried, it was time to remove the pep helmet

http://i307.photobucket.com/albums/n...psjbr02ecn.jpg

Then I started slush casting helmets from it.

http://i307.photobucket.com/albums/n...ps0cooicet.jpg
http://i307.photobucket.com/albums/n...psd1zywfh2.jpg
http://i307.photobucket.com/albums/n...psbpj3alco.jpg

Re: My son's halloween costume
 

so now i get to do some sanding, painting and such. can't wait.

here's the Orioles themed paint scheme we are going with.

http://i307.photobucket.com/albums/n...psjflg4bux.jpg

Re: My son's halloween costume
 

Use the force, Luke

Re: My son's halloween costume
 

Vary cool

Re: My son's halloween costume
 

that's so cool, it's looking great :tu

Re: My son's halloween costume
 

Very cool!

Re: My son's halloween costume
 

thanks

did some sanding clean up last night and cut out the t-visor area. got luke to do a little modeling.

http://i307.photobucket.com/albums/n...psiquolgxb.jpg

went to home depot today and got the paint. going to do an under layer of hammered silver and use the vaseline technique so that you see the metal look under the battle damaged areas of the armor.

http://i307.photobucket.com/albums/n...psi9rixj2o.jpg

Re: My son's halloween costume
 

Little short for a stormtrooper isn't he? :D

Re: My son's halloween costume
 

Holy snikes, count me impressed! Fine job, sir!

Re: My son's halloween costume
 

started painting today. first was the primer and then the hammered silver paint.

http://i307.photobucket.com/albums/n...psbd34pvbr.jpg
http://i307.photobucket.com/albums/n...psgyrocncy.jpg

Re: My son's halloween costume
 

Cool!!

Re: My son's halloween costume
 

Will you be my Dad?http://i156.photobucket.com/albums/t...smiley-004.gif

Re: My son's halloween costume
 

well. after having a heck of time with the first can of orange spray paint that i bought (it was actually stripping the other paint off the helmet when i would spray it on), I was able to get the t-visor area painted with a new can. guess i will be emailing rustoleum about that.

http://i307.photobucket.com/albums/n...psy8ditfex.jpg

also picked this up to go with the costume.

http://i307.photobucket.com/albums/n...psiwvc42ga.jpg

picked up a replacement visor for a motorcycle helmet, marked it and have it ready to cut.

http://i307.photobucket.com/albums/n...psjtqgzcav.jpg

Re: My son's halloween costume
 

Sweet!!!:tu

Re: My son's halloween costume
 

he wanted to try it on. ha

http://i307.photobucket.com/albums/n...pss0ojzfhd.jpg

little wet sanding and clear coat and it will be ready for the visor and padding.

http://i307.photobucket.com/albums/n...psmoeo4a8b.jpg

Re: My son's halloween costume
 

Very nice, I kinda seriously wish I could contract out an unpainted helmet from you. I'm just afraid my big noggin wouldn't fit.

Re: My son's halloween costume
 

Very cool and great work :tu

Re: My son's halloween costume
 

Rob - Now that is a COOL kid! :banger

Re: My son's halloween costume
 

that is some project!

Re: My son's halloween costume
 

This is sick!!!

Re: My son's halloween costume
 

thanks all.


Sintra came in yesterday. So i got it all marked up and ready to cut.

http://i307.photobucket.com/albums/n...psia1iai6g.jpg

Also going another route on the visor. Bought a faceshield replacement and will use window tint to darken it.

http://i307.photobucket.com/albums/n...pszsvslpnf.jpg

Re: My son's halloween costume
 

Armor all cut out

http://i307.photobucket.com/albums/n...pshsvxavc7.jpg

Re: My son's halloween costume
 

broke out the heat gun last night and started forming the armor and then took advantage of the little guy being sick (daddy stayed home with him) to get some painting started.

http://i307.photobucket.com/albums/n...pslihzw3aa.jpg


also put the clear coat on the helmet. now i just need to get the visor cut out and installed.

http://i307.photobucket.com/albums/n...ps2mmrrvys.jpg

Re: My son's halloween costume
 

so yesterday was enough to piss me off. taped up the armor with the design I wanted and proceeded to spray it with the white and orange paints.

TO HAVE THIS HAPPEN.. WTH.

http://i307.photobucket.com/albums/n...pseptqdyoh.jpg
http://i307.photobucket.com/albums/n...psiflnqdg5.jpg


so. I had to strip it all the way down and start over. ughh.

Re: My son's halloween costume
 

got a lot done this evening. After repainting the armor, I wiped the "vaseline areas" off on the armor and put the velcro on the backs of it to get it ready to attach to the shirt and pants.

http://i307.photobucket.com/albums/n...pswhlrck5j.jpg
http://i307.photobucket.com/albums/n...psom109wbk.jpg

and got the visor and LED cable installed in the bucket. it's 95% done.

http://i307.photobucket.com/albums/n...psmhvr9scg.jpg
http://i307.photobucket.com/albums/n...psycwaupyc.jpg

Re: My son's halloween costume
 

Wait it lights up?!?! Like it couldn't get any cooler. Great job, brother! When I was little I spay painted boxes silver and used tin foil and made a robot costume =\ HAHA

Edit: and no it didn't light up :sad

Re: My son's halloween costume
 

Thanks adam. I am excited to see it done and him in it.

and then it is on to trooping together.

Re: My son's halloween costume
 

This is totally awesome -- you have some skills and your son is very lucky!

Re: My son's halloween costume
 

That'll happen if it's too cold where you paint.
Usually the can says what the limits are, but I think the low end is 50*.
It does suck. Very hard.

Re: My son's halloween costume
 

that's what i was thinking, but I got the different metallic paint and sprayed it on in temperatures lower than those shots and it worked fine.

The more and more I talk to people, the more I see people having problems with the hammered metallic paint. almost like it wasn't meant to over sprayed

Re: My son's halloween costume
 

My little Adi'ka in his preschool halloween parade.

http://i307.photobucket.com/albums/n...svkrqklyx.jpeg

Father and Son in our buckets.

http://i307.photobucket.com/albums/n...psgisz6yko.jpg

Re: My son's halloween costume
 

sweet!

Re: My son's halloween costume
 

Coolest Dad ever! :tu

Re: My son's halloween costume
 

Awesome! I hope you get first pick of the candy for that one! :D

Re: My son's halloween costume
 

Very cool, Rob!

Re: My son's halloween costume
 

as my wife put it. the costumes were a hit. she came around the corner, saw the crowd and thought someone was giving out full sized candy bars. NOPE, it was a photo op with me. lol

me and the little guy last night for halloween.

http://i307.photobucket.com/albums/n...psfiqszgtb.jpg

Re: My son's halloween costume
 

Very cool!

Re: My son's halloween costume
 

Very, very cool. It may be a coincidence but my son is named Luke, my name is Rob, he dressed as a clone yesterday, complete with realistic blaster. I went as Darth Vader, the very realistic Vader helmet allowed me to check out the sexy witches without being noticed. Great project for you and Luke!

Re: My son's halloween costume
 

Awesome job on the costume, Rob.

Re: My son's halloween costume
 

so. a little update on this. Luke has outgrown his original bucket so I have started the process of making a new one for him. I am hoping to have it done in time for the Washington Nationals Star Wars Night on August 13th.

made another design from a pep file. Used wall spackle and sand paper to smooth out the dome. Then spray painted it and got it ready for the mold making process.

http://i307.photobucket.com/albums/n...pspaefck4m.jpg

Decided to do a clamshell style mold this time around.

http://i307.photobucket.com/albums/n...psquufe6rp.jpg

back half ready for the rebound 25 treatment

http://i307.photobucket.com/albums/n...ps7bxjaqca.jpg

Re: My son's halloween costume
 

first coat of rebound 25

http://i307.photobucket.com/albums/n...psecleiqjy.jpg

3rd coat

http://i307.photobucket.com/albums/n...psicevhjsw.jpg

4th coat with a thickening agent

http://i307.photobucket.com/albums/n...psgpre3ags.jpg

and now the plastipaste hardshell applied.

http://i307.photobucket.com/albums/n...psslcsxua9.jpg


Now to just let it cure. Flip it and start on the other side.

Re: My son's halloween costume
 

:lr kind of funny he's gonna keep out growing them as fast as you can make them, that's awesome and what a great dad you are :tu

You should be comic con with a booth set up taking orders :D

Re: My son's halloween costume
 

I know. I got smart on this one and made it a little bigger and I have also started on an adult sized one for me. :)


so after getting the one side done I flipped it over and repeated the process.

http://i307.photobucket.com/albums/n...pswkoegpsm.jpg
http://i307.photobucket.com/albums/n...pspyac2elc.jpg
http://i307.photobucket.com/albums/n...psh7dex8nf.jpg

Re: My son's halloween costume
 

finished mold

http://i307.photobucket.com/albums/n...psn3y66be6.jpg
http://i307.photobucket.com/albums/n...pst2eeu17b.jpg

Re: My son's halloween costume
 

and first pulls from the molds

http://i307.photobucket.com/albums/n...psoorfeggi.jpg
http://i307.photobucket.com/albums/n...ps1nqfe0xp.jpg

Re: My son's halloween costume
 

Looking good!