Screen Accurate Sandtrooper Squad leader.
Posted 11/19/13 , edited 11/19/13
Just finished this recently.

Everything is hand made, and hand painted.




Total cost currently $1350, estimated cost with Sandtrooper backpack+electronics+helmet electronics+blaster+DLT-19 Blaster= $2350.



Below are some rough build shots from box of armor forms to worn.

http://imgur.com/a/UtxF0





Feedback?
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Posted 11/19/13


Woah, nicely done! Did you go with vacuuforming, or fiberglass? Or both?
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Posted 12/15/13
Wow this is awesome! I am thoroughly impressed! Have either of you gentlemen used wonderflex before? I'm looking at it to make some armor, and I'm trying to find some first hand opinions on it.
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Posted 12/18/13
WOW very nice!
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Posted 12/19/13

JingjoLee wrote:

Wow this is awesome! I am thoroughly impressed! Have either of you gentlemen used wonderflex before? I'm looking at it to make some armor, and I'm trying to find some first hand opinions on it.


I used it briefly.. it's a neat material, lots of folks love it. If you are able to do some simple curves for your armor, it should work great. Doing more complex curves (like sphere shapes) is harder, though, and a lot more cleanup work afterwards. If you go with it, I'd also suggest getting a small jar of Friendly Plastic pellets. They're a similar thermoplastic, so you can melt them into the Wonderflex for repairs and cleanup.

You might also check out Worbla. I've heard it starts out smoother than Wonderflex, so it might be even better for your armor needs.

Only reason I don't use it for more armor is that I prefer other approaches for the way I work. Craft foam is fantastic for making shapes, and if you hot glue two layers of it together and then use a heat gun on it, you can shape it more easily than Wonderflex. Of course, it's just foam, so you'd have to coat it with something like fiberglass resin (like I did for the gauntlet in my profile pic) or another material if you need it to be strong, but there are lots of ways to do that.
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Posted 12/19/13

MakotoKamui wrote:

I used it briefly.. it's a neat material, lots of folks love it. If you are able to do some simple curves for your armor, it should work great. Doing more complex curves (like sphere shapes) is harder, though, and a lot more cleanup work afterwards. If you go with it, I'd also suggest getting a small jar of Friendly Plastic pellets. They're a similar thermoplastic, so you can melt them into the Wonderflex for repairs and cleanup.

You might also check out Worbla. I've heard it starts out smoother than Wonderflex, so it might be even better for your armor needs.

Only reason I don't use it for more armor is that I prefer other approaches for the way I work. Craft foam is fantastic for making shapes, and if you hot glue two layers of it together and then use a heat gun on it, you can shape it more easily than Wonderflex. Of course, it's just foam, so you'd have to coat it with something like fiberglass resin (like I did for the gauntlet in my profile pic) or another material if you need it to be strong, but there are lots of ways to do that.


I've heard for smooth rounded contours, wonderflex isn't the best and it's sister fosshape is recommended; however fosshape isn't really something you would use for armor...

And I hadn't heard of gluing two layers of craft foam together, then blasting it with my heat gun! That is definitely something I'll have to check out. How would you say the price of that process (craft foam, hot glue, finishing material) is in comparison to wonderflex (which after shipping, is nearly $50 per 43" x 55" sheet).
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Posted 12/19/13
It looks great but you know it has to be said, "Aren't you a little short for a stormtrooper?"
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Posted 12/20/13

JingjoLee wrote:

I've heard for smooth rounded contours, wonderflex isn't the best and it's sister fosshape is recommended; however fosshape isn't really something you would use for armor...

And I hadn't heard of gluing two layers of craft foam together, then blasting it with my heat gun! That is definitely something I'll have to check out. How would you say the price of that process (craft foam, hot glue, finishing material) is in comparison to wonderflex (which after shipping, is nearly $50 per 43" x 55" sheet).


I buy my craft foam by the roll - it's usually under $15 for 36"x60", and I try to get free shipping on it if I go to Amazon, or they'll usually sell it at Michael's Arts & Crafts or other stores if you have them locally. Check in the kids' crafts section, I think they're about $12 in store. I stocked up last time they had a half off sale, so I probably won't have to buy more for years. So base material is far cheaper, and easier to shape as you like, especially if you use a heat gun.

Whatever you coat your armor with is where you'll really feel the price hit, though. Some people go with fabric backing instead, and coat the front with combinations of paint or other materials - check out this tutorial for some details, I know lots of people suggest it as a great primer.

I like armor hard enough that I can walk on it to make sure it doesn't break in transport, though, so the gauntlet in my profile pic has about $15 of resin and maybe $7 of bondo invested in it. It used about 1/3rd a sheet of craft foam, so my total cost was around $26 in materials, while in Wonderflex it probably would've been closer to $17, if I could get it to cooperate with the shapes I wanted. I'm not sure how the strength would compare to my coated version.

Pretty sure I spent more on paint than anything else, with the primer, chrome, colors, and clear coat, but with larger armors, that would flip back to the materials costing more than the paints.
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Posted 1/16/14
OP nuked.

Feel free to recreate.

~Locked
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