After watching many Treads and finished Costumes here, i decided to make the Armor for my Client out of Foam.

Ragnar´s Progress Pics are guilty for that Decision, thx!

I modified the Pep-Files from the Mk7 Armor Files from Ral Partha, so there are less to cut and glue, and smoother.

The Work i´ve done this far proves that i made the Modifications correct.
Parts are very smooth and i don´t need much Fiberglas, if the Client wants it stronger.

Parts were made in 2 Days and i think i should have it done this or next Week.
I don´t use Hotglue, but a special Glue that connects the Foam under 1sec.
Some Spots are open, but no Problem at all, happened because of the Foam-Strength.

Results also have the Sizes i need, Client has pretty much the same Meassurements i have, so i can make it fit me too.

The most Parts are Foam, except the Shoulders and Helmet.
Helmet will be made the regular Pep, Fiberglas and eventually Mold&Cast Way.
Shoulders need to be smooth, so i make the Base out of Styrene and Urethane Sealing.

At the Start of making this, i thought it would take more than 3 Months, but i am sure i get it done in 1 or 2 with all Details. No Stress also, but i love to make this Armor more and more.

So, less Talk, ore Pictures. I jsut have only 3, but that is gonna change rapidly.

Looks good, the arms look very clean.

I worry that the shins are a little to small however.

It´s all calculated, Changes can be made anytime.
It´s not going to look 1:1 like a real SpaceMarine, he want to use it for LARP so i have to make it a little Custom anyway.

Shins are 40cm high, Boots are not going to be very high, but wide enough so they are closing with the Shin Sides.

looks decent. i too think the shins are small and the arms are narrow.

but, it is hard to tell without a person in them.

what glue are you using? why not hot glue?

I use a big Bottle of Powerglue from Toolcraft.

Hotglue needs too long and i don´t want to get burned again^^
This Glue hold the Foam together like it was never seperated.

I´ve tested the Parts on me, they have a good Scale.
You´ll see that on the next Pictures.

your foam build looks really good.

depends on the hot glue. hi temp glue sets in about 1-3 seconds. that's not long at all.

If you think that's too long you're rushing.
if you are getting burnt. you're rushing

slow down.

Nice start. :)

I'm with you, can't stand using hot glue it's too messy and gets everywhere.

im not sure how hot glue is messy and gets everywhere. go slower, use a proper glue gun that doesnt have a large hole to expel the glue (ive seen them, this may be your problem) get one with a small, maybe 1/32" hole.

hot glue used right does not make a mess, burn you or take longer than a few seconds to bond most anything. if it does, youre using FAR too much.

trust me on the glue and foam thing.

If his method is reliably bonding the material, which it seems to be, there's no reason he'd have to use hot-glue. It's a 'traditional' standard in this medium, true, but just because it's been around doesn't mean it exceeds above all other. Don't fix what ain't broke, and this chap and his method seem to be in working order. Hotglue also can't be sanded or shaped at all/very well, whereas most epoxies or glues can, excepting elmers style white glue. Though in the case of locktite, is smells.. *BAD*

Though I agree, with proper application and a correctly sized applicator, hot-glue is hard to beat. However, I have had it melt on me.. It seems just heat can make it melt, but the high temp stuff I used also seemed to react to humidity just as much as heat in so far as softening.

ive stood outside in over 120 degree weather without the glue melting for over an hour.

anyway... im not saying he shoudlnt use it. but njo clue if its far more expensive. i can build more than one suit of SM armor with a 100 stick bag. my guess is about 6-8 sticks per kit.

the only time ive had HG fail is on vinyl in the desert. abotu 116 no humidity

I´ve used Hotglue for my Reach Armor, and it took very long.
It works good and they still hold when i bend them.

AS for Rushing, i have no Reason, i am just very fast on building the Base for Fiberglasing after.

That Glue that i use is a 50gram Bottle of industrial SuperGlue, and it´s cheap...and the Client payed it^^

I have about 4 Years of Experience behind me and 1 Year with Foam, plus SpaceMarine Armor is very LowDef in Pepakura.

Details will be added after Fiberglasing, and that´s the Point where i need the most Time then.

Sculpting the Wax-Logos they have on the Armor, find the correct Paper for the Seals and print the Graphics on, adding Mounting Devices, etc...

Double Post, wuhu!

Finished the Torso today, Scale is correct what the Width belongs, and for the Hight..there is missing a little Part, but that will be attached when the Client says that the Size is okay for him.

Took about 5 Hours from Template Cutting to glue together.
Also added Hotglue on the inside of the Neck Part for a better Hold.

Good looking chestplate, looks very clean. I do think it looks a bit small. Do you have any photos that shows any kind of scale?

It´s scaled to 450mm Width, i weared it and it i fits good, it ends exactly at the Upper Arm.

I don´t know if it´s a little small for the Height, i am making also the Part that is between Torso and Belt. But that is the best at Foam, if i need to add something more, i just glue and cut.

But i can´t overscale it anyway, since he want to use it for LARP, there is a Compromise to accept between Look and Movement.

At the Weekend i know more, that´s the Time he gonna wear the Parts.

Shoulders need the most of the Time i think, need to be PERFECT round and smooth.

I wish i had a Vacuumtable or someone in Europe who sales some formed Shoulders...but at a other Point of View...more Work for meeeee!^^

how tall is your "client"?

I only ask as i am not very tall; 5'7" at best. I use the 500w x 780h torso scale. that scale is a bit oversized for me but i think it looks perfectly proportioned for shorter people.

the other armor im building is for up to 6'7" people and been using the 850 and 900 scale torsos.

the legs and arms are all customized sized to the people as everyone is different.

as for movement. my version 1 armor, is not nearly as maneuverable as the templates we both are using. i can easily clib stairs run and such in this armor. so far...

if it IS for LARPing, accuracy should be at the top of his list, unless its a SCA thing whereas protection would be highest on the list.

I, and we are here to help you. I have over 20 years costuming experience and while I only have 2 years of space marines armor building, I have built now 7 sets of armor mostly from Ral Parthas files out of foam. so any questions or problems that arise i am more than happy to lend a suggestion.

If any of my suggestions seem "harsh" it is just the way I am with costuming. I would expect people to do the same with my own creations, as most of us already know.

I dish it out, and would hope to receive the same. we should all strive to be the best here.

edit: i looked at your pictures. which files are you using? as you said, they are low res versions. why not use the hd type files that much more detail and curves and whatnot in them?

Nono, not that Way, i am happy that i get Help^^

7 Sets? Well....for every Day in the Week?

The Client is about the same Size i am (1,80m), but he is a little thinner than me, that´s why i build the Armor based on me and how i can move in them, if he wants it bigger, i just need to modifiy some Spots or make a new one, no Problem with that, it´s done quickly.

I use Ral Partha´s MARK VII ARMOR (game rips by Shazmybot) Files.

I saw the Vakuumformed Armor from Thorsolli´s Tread on the 405th with the complete Armor on. Well it IS very accurate, but too big and you maybe need a Dodge RAM or M3 Bradley to get the Parts in a Car.

I´ve seen his Car, and if i make them accurate, he is the only Person that can fit in the Car. And he wants a Jumppack, that must go IN the Car too.
We see it anyway at the Weekend, and i have pretty much Time for Changes.

I don´t know LARP very good, but a full sized Marine that can´t see the Bottom is not very safe i think, and i don´t know if they are playing in the Woods too, so it would be unsafe.

I would say we are in the Middle Section, between a accurate SM and the Suite that Djinn made, wich was in the Discussion first from his Side.

This is the first Time i make a Armor that has nothing to do with HALO, but i am having more and more Fun to build that Thing after every Part.

true.

however even with NO helmet, you wont see your feet at all.

and i only have two sets. the rest is part of the local group starting here. they are all in my house at the moment though as we build them.

they dont look the same as the files i'm using from RP.

youre looks like a very low res version.

Client weared it today, the most Parts are calculated correct, the Thighs need to be 14cm higher and broader, the Torso a little shorter at the Depth from Front to Back.
Also the Shins need a little Modification at the Section where the Shoes getting connected to it. No big Deal at all, done in an Hour.

All in one the Armor is perfect for him, so i can add Fiberglas the next Weeks.

Did I miss something?? :huh: Why are you adding fiberglass to foam armor? Usually the reason for doing armor in foam is to avoid all that fiberglass and bondo nonsense!! :unsure:
;Ultrasmurf;

i agree. i think i missed that.

why are you adding FG? foam does not need it.

if you need to seal it, use brush on acrylic paint, modgepodge or a 1:1 mix of elmers white glue and water.

EDIT:



i woudl also comment that I have zero experience adding FG to foam. it may eat it, it may not. i wouldnt take the chance.

there is no reason at all for FG to be added. if the armor is done being constructed. start the priming and painting process.

also please post pictures.... im curious as to why depth was eliminated in the torso. that is what gives the armor is huge look.

not that it maters now, but i can fit 2 sets of armor and two people in a chevy Aveo. its smallest car in the fleet. so size shouldnt matter. nor shodul it be your problem as a creator/builder of said armor, as it the "clients" issue.

I hate to ask, but I am curious. how much is he/she paying you to build this stuff?

I´ll test that before fiberglasing the Parts.

He wants it smooth, what the Torso belongs.

If the Test-FG is okay, i reinforce the other Parts also.

Pictures: http://www.armorcorp.at/?page_id=423

If i only FG the Torso, the other Parts are sealed with PlastiDip.

The Foam also can be sealed with Polyurethan Resin and Fiberglas instead of Polyester Resin (the Stuff that gets very hot).

looks pretty good. still think the torso/chest is far too small

Maybe, but he was happy with it, i said that i can make it bigger if he want that.

I also make the Underarmor between Belt and Chest, i think i am gonna install Velcro on the Inside of booth Parts and use a thin Foam Rubber around it, hold together by the front Plate with the Hoses or whatever regular Space Marines have there.

I also got the Coloring Pattern that he wants:

http://wh40k.lexicanum.de/wiki/Imperial_Fi...s)#.T2zKhBEf4sJ

ohhh, imperial fists are awesome.

over here in the Southwestern Front Chapter, we figured out a straight piece of 1/2" foam with 1/4"x1" ribbing works nicely.

its not attached on top just in the back by quick release buckles and in the crotch by some nylon webbing running underneath

Sooo...long Time no Update, ´cause i am 6-8 Hours straight in my Workshop, improving the Parts and Size, etc...

I got also the 3rd Purity Emblem done, the Papers too, printed on a special Paper, Pics tomorrow.

I got the Torso fiberglased and smooth with about 2kg of Rondo & Bondo, was a nice Week to smooth it, but it was worth the Work.
And yes, EVA Foam works with Fiberglas and Polyester-Resin very good, it doesn´t melt the Foam or anything else.

I also made the Helmet, 2 Days of Pep-Work and 2 Days for Rondo/Bondo and Smoothing. This is a old Picture, today i made the last Steps to get it smooth and round, i just need to make the Parts for the Ears, Hoses and Mouth, then buy some Rebound25 and mold it.

After i painted the Torso, it looks really a little small to me, but the Client said it was perfect for him, so i have no Problem with it.

(@Ragnar: It seems that i got the SAME Torso Size like you have, at least what i can tell from your Pictures^^)

Any Advice, of what Material i should make the Wings for the Front?
The Skull is not the Problem. But i don´t know what i should use for the Wings.
PVC-Plates? LARP-Foam?

Lookin' good so far.

Sry for the Delay, i am in Stress every Day since 3 Weeks.

do you have the PDF or Ai files for those? be nice to have them available to those who need them.

:)

I am making more of them, then i make a RAR File and upload them on my Server.

In could also make some based on your Ideas and Quotes, if you want.

UPDATE!

Let the Pictures talk^^

http://www.armorcorp.at/wp-content/uploads/2012/03/Arms.jpg
http://www.armorcorp.at/wp-content/uploads/2012/03/Chest.jpg
http://www.armorcorp.at/wp-content/uploads...Arms-Detail.jpg
http://www.armorcorp.at/wp-content/uploads...elmet-done1.jpg

Done this Week:

Hinges for the Arms (Testing...)
Helmet nearly done for Molding
Chest painted
And some other Things that i post when they are done.

How did you get the chest so smooth and seamless?

Fiberglased EVA Foam^^

Damn, fibreglass :( Anyways, it looks like a really nice suit you've put together. I was hoping you had a secret trick with foam you'd share ;)

a RAR file? m y PC deletes those upon downloading i think the microsoft firewall/security hates them.

Can you email out PDF's or similar? or at least post up the files in photobucket at full size?

I can make a ZIP also, don´t know why the Wincrap Firewall blocking RAR Files, but that can be changed.

That's not Windows Firewall. That sounds like an anti-virus set to aggressive.

i dotn think either is necessary I would think the minute size differences dont warrant a zipped file at all.

Bolter NERF Shell near Finish Line: