Wow, I can't believe I haven't posted progress pics of this yet..
So this other guy I've been working on:
Is a project that consists of three parts: the sword, the guard, and the scabbard. I get to try 3-5 new techniques here!
This is an early pic. It's 1/4 MDF reinforced on either side with 2 layers of fiberglass, and a coat of Bondo Gel.
Starting out on the shapes for the guard. I used that pipe saw to cut through the styrofoam quick.
I assembled the 3 foam pieces, and slapped a layer of Plaster O'Paris/Burlap over it. I did this mainly because it's much faster than sanding 3 styrofoam pieces round.
There's a step missing before this pic. I covered the burlap piece with Super 77 spray and layed on some aluminum foil. Then I put 2 layers of fiberglass on.
Wait, nevermind. I found the pic of the previous step. It looks like this. Nothing too exciting. Shiny side up, or down? I can't remember!
Glop on some Bondo Gel and you have a nice little turtle shell that you can sand.
Sorry, no turtles in here, but I do have a shell that's about as hard as one. If you're thinking about making some armor, make a paper mache or foam or whatever positive, and follow this process. This thing is ROCK SOLID.
A little bit of sanding and now it looks more like a Psyduck.
Same technique here, only I need two halves to assemble into a hollow shell.
Foil, fiberglass, and pop off the molds!
I trimmed the edges of the two halves so I could join them....somehow.... I've got some "fiberglass resin tape" I made that should hold the halves temporarily until I can add...
Some more of this shit! (you can see the two halves trimmed and kind-of put together on the right)
Seaweed is nature's cement. I put my "fiberglass tape" pieces across the seam, and then added more Bondo gel over the top. It won't be as strong as glass cloth across the crack, but it should work. The glass cloth wouldn't sit right and you can't sand it, so I figured it'd be best to just use sandable materials and build up, and then start shaping it. Also, LOL DONGS!!!
So that's where I am with this one. I 'm out of polyester resin, and I have a headache, so I might pack up in a bit and call it a day.