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 Post subject: The BIG one-Metal Armor project ("Hudson" Repaint, DONE pg5)
PostPosted: Sun Aug 09, 2015 7:53 pm 
THAT guy
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Location: Virginia
Service Number: A03/TQ2.0.02146E1
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My various pulse builds were challenging. The smartgun build continues to be a work in progress. However I suspect nothing can prepare me for what I tackle next.

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With some mostly very basic (and mostly pretty cheap) tools, with a little ingenuity, a bit of luck, and more than a little patience, I think I can do this...


Last edited by bigbisont on Tue Nov 17, 2015 6:28 pm, edited 4 times in total.

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PostPosted: Sun Aug 09, 2015 7:54 pm 
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I know you can! Jealous!

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 Post subject: Re: "The BIG one". Getting ready to start my ultimate projec
PostPosted: Sun Aug 09, 2015 8:32 pm 
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Location: Wolfsburg Niedersachsen
Service Number: A12/TQ2.0.02132E1
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I know what your going for, and i wish you all the luck in the World mate,but i'm shure you whon't Need it.
I'm pretty sure we are going to See another Set of self made armour comming Up,and if looking at all the stuff you have made in the past i'm sure it's going to be a piece of art.

Neil

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PostPosted: Mon Aug 10, 2015 7:14 am 
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Cool project! Can't wait to see how it all comes together!

Steel or aluminum?


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PostPosted: Mon Aug 10, 2015 2:41 pm 
Proceed on a 2-1-6...
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Wow! Good luck buddy!

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 Post subject: Re: "The BIG one". Getting ready to start my ultimate projec
PostPosted: Mon Aug 10, 2015 5:01 pm 
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Location: Germany
From the experience with my armor I can tell you that you won't need most of it.
What you really need are:

1. 1.5mm sheet aluminium (0.8mm won't keep it's shape and anything thicker than 1.5mm will be really hard to work with)
2. Two differend sized rubber hammer (small and large) for the shaping of the armor. I tried the ball headed steel hammers and their impact is too localized to get a good shape.
3. Several hard wood blocks to form sharp (90° or 45°) edges and a plastic hammer.
4. (Access to)a beading machine to form the steps and beads on the armor (see here: http://www.hotrod.com/how-to/additional-how-to/1405-beading-machines-for-sheetmetal-work/).
Look for one with at least 25cm throat depth to form the recessed areas on the left and right side of the back.

Cheers,
Stefan

PS: The most difficult part is the back of the leg guards because the have a complex 3D shape and very little space on the inside to "swing" the hammer.


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 Post subject: Re: "The BIG one". Getting ready to start my ultimate projec
PostPosted: Tue Aug 11, 2015 1:19 am 
THAT guy
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Location: Virginia
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Thanks for the tips Bug Stomper. While I'm sure a beading machine would make things much easier (and prettier) I think I'm going to have to attack those edges the old fashioned way. I don't have access to the seemer and can't justify the cost for one project. I think that will be the part needing the most patience and most practice. Except for possibly my welder at work (more on that shortly), I plan to use only hand tools.

nickdaring wrote:
Cool project! Can't wait to see how it all comes together!

Steel or aluminum?


Both! This could be a classic "shortcut" that ends up creating more work than it saves, but like my other projects I planning a few "cheats".

I have acquired a mostly generic steel breastplate and greaves. They are nowhere near perfect and removing inaccurate details may be just as much work as adding correct ones, but I think the largest portion of shaping is done on them already and I can work with it. I will be practicing heavily on basic sheet steel before I take a hammer to either of them, but on those, if I screw up I can at least cut the rubbish part out and weld in some fresh steel.

Of course working with aluminum will hopefully be much easier with the hand tools so for everything else I plan to work in aluminum. PLUS of course when the paint chips, I want that aluminum shining through as much as possible (not steel that may rust if paint is removed). So I think both materials have a place here and have a specific job.

Thanks for the confidence inspiring words everyone and if there is anyone else with experience and advice/tips, I would love to hear more!


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 Post subject: Re: "The BIG one". Getting ready to start my ultimate projec
PostPosted: Tue Aug 11, 2015 3:54 am 

Location: Wellywood, New Zealand.
Service Number: A10/TQ0.0.82146E1
Country: New Zealand
bigbisont wrote:
This could be a classic "shortcut" that ends up creating more work than it saves, ...


:D :D :D
Yup, I can totally relate to that comment.

P.s. Also, very much looking forward to your project progress updates 8)

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PostPosted: Tue Aug 11, 2015 6:01 am 
Mobile Mayhem
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Location: Rapid View, Saskatchewan
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Good luck Terran, I know you'll knock it out of the park like always

My Mom and I keep trying to get my Dad into the idea of armour making, like medieval armour and such but you know I would get him to try Colonial Marine armour if he did try it! He's pretty much an expert with sheet metal, he can mould it like clay. Wish he would open his mind and not just use his talent on "horse stuff" haha.

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PostPosted: Tue Aug 11, 2015 2:21 pm 
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Are you going to tackle the upper body armour first?

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 Post subject: Re: "The BIG one". Getting ready to start my ultimate projec
PostPosted: Tue Aug 11, 2015 5:43 pm 
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Location: Germany
Steel armor? Cool!
You might know this already, but I found it very helpfull:

http://www.arador.com/armour/downloads/Basic-Armouring.pdf

Cheers,
Stefan


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 Post subject: Re:
PostPosted: Wed Aug 12, 2015 1:13 am 
THAT guy
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retrogarde wrote:
Are you going to tackle the upper body armour first?


Actually I think I'm going to start with the cod piece! Should be simplest thing and hardest to screw up. The ab and tail plates next. I will probably do the upper body last because I'd like to have the hang of things before I tackle the pauldrons. I expect those to be hardest.

Bug Stomper wrote:
Steel armor? Cool!
You might know this already, but I found it very helpfull:

http://www.arador.com/armour/downloads/Basic-Armouring.pdf

Cheers,
Stefan


Great little book. Thanks again!


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PostPosted: Wed Aug 12, 2015 3:53 am 
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Location: Phoenix, AZ USA
I thought this might be about hand hammered aluminum pulse rifle shrouds. Good luck with your armor build!


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 Post subject: Re: "The BIG one". Getting ready to start my ultimate projec
PostPosted: Wed Aug 12, 2015 8:41 pm 
Jigoku e masshigura
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Service Number: A06/TQ0.0.32122E1
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Outstanding! A new metal armor build project! Really looking forward to seeing it come together. 8)

Best of luck and um... watch your fingers! :wink:

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PostPosted: Thu Aug 13, 2015 1:09 am 
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Location: Lancashire (Wirral born)
Service Number: A04/TQ1.0.32156E1
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Get on it Marine!

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 Post subject: Re:
PostPosted: Thu Aug 13, 2015 1:16 am 
THAT guy
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88reaper88 wrote:
Get on it Marine!


HA! Believe me I'm trying. This is the work week from hell. I hope to get a big "supplies" shot this week and gather more materials by the coming weekend so I can start hammering and cutting. The supplies part is moving at least. Got just about all the bits I need. Just about...


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 Post subject: Re: "The BIG one". Getting ready to start my ultimate projec
PostPosted: Wed Aug 26, 2015 8:17 pm 
THAT guy
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Location: Virginia
Service Number: A03/TQ2.0.02146E1
Country: United States
Not much to report yet. Still gathering supplies.

This is what I am working with so far.

These are my 'mostly generic' STEEL armor bits I mentioned earlier. Getting rid of innaccurate ridges and imprinting correct ones should be fun!
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Also an m1 steel pot (of course).


This is where I thank various board members for their various offerings!
Big thanks to Noble (bindings, brackets, and ab-pad), Moosh (name stencil), Spat (radio pouch, camera)
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Some real fun parts! A real pentax lens and a real Beyerdynamic HM560 mic. Not a dutch sleeping mat, but an OD sleeping mat.
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And boring parts. Lots of 1" & 2" webbing with lots of fastex & cam lock buckles.
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I have some "cheat" aluminum items on the way which I hope might save me some labor. Some pre-dished materials that I have high hopes for.

Hoping actual progress can soon be made!


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PostPosted: Wed Aug 26, 2015 8:40 pm 
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Awesome!

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 Post subject: Re: "The BIG one". Metal Armor project. (WIP)
PostPosted: Tue Sep 08, 2015 2:20 pm 
THAT guy
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Location: Virginia
Service Number: A03/TQ2.0.02146E1
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Finally! Progress!

So first step was making paper templates of everything I planned to hammer from the aluminum.
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Then I traced the paper templates on to an old aluminum saucer "sled". (they are not real easy to find, and often come pretty beat up, but really arent that much more expensive than sheets of new 16g aluminum and are already 'dished'. So I was quite happy with the results).

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Cut em out

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Then start hammering! (After reading up on techniques and dozens of 'how to' armor making videos on youtube)
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I actually ended up using damn near everything I posted above plus a vice. The vice was a life-saver when it came time to holding my 'stakes', holding the anvil itself, and hammering in ridges.

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One aluminum sled was not enough, so I have sourced a 2nd one. I hope it arrives this week. Working with the aluminum was actually damn pleasant. Patience and multiple passes is key, but I'll be damned it ended up really fun and satisfying.


Last edited by bigbisont on Tue Sep 08, 2015 2:27 pm, edited 1 time in total.

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 Post subject: Re: "The BIG one". Metal Armor project. (WIP)
PostPosted: Tue Sep 08, 2015 2:24 pm 
THAT guy
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Location: Virginia
Service Number: A03/TQ2.0.02146E1
Country: United States
No one will be confusing me with Terry English any time soon, but so far so good! I am happy.

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Here you see when a bit too much force was used and I punched through on the bottom ridge of the lower lobster plate.... ugh. But when painted no one will see it. (I hope)
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Regarding the pauldrons, I wish I had done the square indentations/details on them BEFORE I hammered and formed the edges. Attempting to do them after warped my shape pretty badly. They aren't nearly as pretty now as they were in that pic! So, if anyone is attempting this, remember that tip.

Overall everything needs a ton of cleanup. I want to get the chisel marks out but I am pretty fired up.


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PostPosted: Tue Sep 08, 2015 2:29 pm 
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Location: Perth Western Australia
Service Number: A07/TQ2.0.02251E1
Country: Australia
Looking very good thanks for sharing your progression.


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PostPosted: Tue Sep 08, 2015 7:28 pm 
Harvester of Sorrow
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Wow! Your kicking ass mate!!

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 Post subject: Re: "The BIG one". Metal Armor project. (WIP)
PostPosted: Tue Sep 08, 2015 9:47 pm 
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Service Number: A01/TQ0.0.12149E1
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A - M - A - Z - I - N - G

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PostPosted: Wed Sep 09, 2015 2:53 am 

Location: Wellywood, New Zealand.
Service Number: A10/TQ0.0.82146E1
Country: New Zealand
Dude! That's turned out *really* well! It may not be TE-standard, but I reckon once it's got some paint / weathering on it, it'll just as good as the 'real' stuff. Very nice work ... must resist the urge to give this a go ...

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Last edited by septic on Wed Sep 09, 2015 9:31 am, edited 1 time in total.

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PostPosted: Wed Sep 09, 2015 7:35 am 

Service Number: a02/tq2.0.12143e1
Country: Australia
awesome so far. well done


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