Monday, May 1, 2017

Project Iron Man #1 Foam Fabrication

     I have started building an Iron Man costume, based off of the Mk. 6, from the movie Avengers. This post is covering the suit itself, and I will have a 2 follow up posts with a post explaining the electronics, and another to show the concluded project. This post will detail foam fabrication, which is how I am going to build my suit. This type of costume making is very popular for quite a few reasons. It is fairly cheap and easy.
Image result for iron man mk 6

      Above is a reference picture of the iron man suit itself. This is what it should look like after painting. Below is a picture of my personal suit, which is blue, because my foam is blue. I will fix that after painting. The way I constructed this suit is very similar to my hulkbuster pepakura. I am using the Pepakura software again, but I have now purchased the premium edition, so I can change the scale of the model to fit me. For foam costume making, find the costume model you want, and print out the template sheets. Once you have you temples, cut the foam pieces out as you go, otherwise you end up with a mess. Cut out your piece of paper, and trace it onto some foam with a sharpie marker
. Any type of shop floor mat will work for this. Cut out the piece from your foam, and hot glue the pieces together as the computer software tells you to!

    That is almost the entire fabrication process. Next, is painting. Since we are using foam, we cant use paint immediately, since the foam would absorb the paint. You need to coat the foam in a thick substance first, I use Plasti-dip, a rubber based spray. 2-3 coats of plasti-dip is recommended, but you can just keep painting until you no longer see the base color of your foam. After the plasti-dip is dried, you can paint the foam just like any other material. That is all there is to it! Stay tuned for future updates, and thanks for reading.

Monday, February 13, 2017

How I got Started in Movie Replicas

     I was recently asked to talk about how I got started with replicas, and I decided to make up a post rather than just explain in the comments.

     All of this started back in 5th grade, when I saw toy light sabers in stores. Every time I saw one, I begged my parents to buy it. My dad always said, "It would be more fun to build one anyway!" and he wouldn't let me buy it. After lots of begging, I started making stuff out of LEGOs at home. My dad was right, and it was much more fun than just buying the toys pre-made. It all escalated from that point, and I eventually discovered Adam Savage and Tested, a YouTube channel I watch a lot.

     Adam Savage is a professional prop maker. He makes props we see in blockbuster movies! On the YouTube channel Tested, I have learned a lot from him on his building techniques, with more than 100 videos of his props! A new video of his builds comes out about monthly, and tested itself also releases videos daily. If you are interested in my blog, I suggest you go and check out Tested.

Monday, January 23, 2017

Project BB8 #1 The Plan

I am starting to build a BB-8 replica from Star Wars The Force Awakens. BB-8 is sphere-shaped, and he rolls around. This is a VERY common droid for pros to replicate, and I decided to try it.

This is the stuff I am using for my project.

  • LEGO Mindstorms NXT Robotics kit (you can use a much cheaper solution, I had this laying around)
  • A 30 cm Beach Ball, this is my base for the sphere
  • Paper Mache, and Automotive body filler (a little advanced for a beginner)
  • Neodymium Magnets
  • Spray Paint (Orange, White, Black)
  • Old Straw Hat (Head of BB-8)
  • Paper (Stencils for BB-8s side designs)

At this point, I have the internal robot structure and have started coating the body.

The electronics for BB-8 is really simple for code. I built a System that goes inside the ball. There are 3 motors, 2 that drive the robot around, and the third can control head rotation. The head will stay on using 2 of the magnets, which are really strong.

This picture is very similar to the type of droid I am building.

The droid is all being controlled with Bluetooth, and an app on a tablet (android). The Robot itself is just using built in Bluetooth firmware, so there is 0 coding involved.

For the ball, I started by covering the beach ball in 3 layers of Paper Mache. This is giving the body filler something to cling on to. This is where I am currently working. I am covering the beach ball in auto body filler to give the ball some more structure. I plan to put magnets inside the ball so it can stay together.I have applied 2 layers to the body, and this is a picture of the ball half covered with the filler.

I've also applied body filler to the head. The head is part of a straw hat, with a layer of paper mache.

Once I have finished filling and sanding, I am going to paint the droid. After Painting this project should be pretty much done!

Stay tuned for some more updates, I'll have a video up by the middle of February!

Saturday, January 7, 2017

Captain America Shield Clock #2 It's Done!

   As you may know, The Plan was to 3-D Print a replica of Captain America's Shield, with it doubling as a clock. My plan completely worked! I have finished the clock, with it only costing about $20 (3D Printer not Included). I will post a video Build Summary soon, but for now, I have a text tutorial and some pictures.


     It all started at my computer, with my 3D Modeling software, Autodesk 123D Design. This was my first custom 3D model, and It was a little tricky. If you happen to have your own printer, I have posted these files up on Thingiverse, so you can make your own. Once I printed out the parts, I hot glued them all together on top of a poster board. This was mainly so I could make the clock a bit thicker, as the print itself isn't even an inch thick. Now, you need to buy some clock parts. I needed a long shaft clock, so I went with this kit off Amazon. Next, you need to drill a hole down the center of the shield, so your clock parts fit. First, use this guide to find the center of the clock (I did it on the back). Grab a drill, find a bit that is about the same size as the clock shaft, and drill through the shield! Try not to use a super high speed, this can melt the plastic through friction. Next, follow the instructions for the clock parts, putting them on in the order specified. Once you have the clock parts installed, put in some batteries, and you have a shield! Hang it up, and impress your friends!

  Thanks for Reading! Stay tuned for future updates on my other projects!

Monday, November 21, 2016

Captain America Shield Clock #1 The Plan

 My plan is to 3-D Model and Print a Captain America Shield, that doubles as a clock! I am going to design the shield in Autodesk 123D Design . This was pretty hard to model, being one of my first things, but I think I got it pretty good. The shield is designed in multiple parts, so I can print in different filament colors. After I've finished printing the shield, I am going to glue it onto a stiff poster board for support.

Here are pictures of the individual components.

Image result for captain america shieldThis is what the shield looks like fully assembled, compared to an actual shield prop.

After everything is glued in place, I am going to drill a hole through the center of the shield, and insert the clockworks. My next post on this project will be a build log video and pictures of the finished shield.

Friday, November 4, 2016

3D Printing Lesson #1 The Basics

This is lesson #1 of my series of 3-D printing posts.  Today we will be covering the basics of 3-D Printing.

     3-D Printing, also known as rapid prototyping is the process of using plastic or other materials to make a 3D object. There are 2 types of 3D printers for hobbyists today-

Image result for cartesian 3D printer diagramImage result for 3D printed objectsFused Deposition Modeling, or FDM is the most popular design. Put simply, the printers are like a motorized hot glue gun that automatically dispenses plastic instead of glue. This is all controlled by a computer, and the movements can be very precise. There are filaments other than plastic, but PLA and ABS plastic are by far the most popular types. This filament comes in big spools ranging from 20-50 US dollars.
    This is a Benchy, a 3D printed boat designed to be used to test your printer's quality. This Benchy is Printed using the FDM type. If you look really closely, you can see separation lines between layers. This is the printer type I will talk about more, since I have one of these.

Stereolithography or SLA is a way more complicated version of 3D printing. SLA uses liquid resin and light. This printer has a laser or projector on top that uses tiny beams to cure (solidify) the resin into a shape. The elevator rises the platform up and down, slowly building up the shape. This process is a higher quality most of the time, but these printers are much more expensive. Below is a SLA printed Benchy. You can see almost no layer separation on this print, proving that quality boost.

Image result for sla printer diagramImage result for dlp printed benchy
Another Essential to 3D printing is a slicer software. This software generates instructions for the printer to follow. These software's are almost all for Computers, but apps and internet based services are slowly coming out. These are 3 very popular Slicers, CuraSlic3r, and Repetier. These all export G-Code, which is widely used by most 3D printers, although some do use a custom type.

CAD  is the last element. Autodesk  is the software i use. This is all up to your personal choice. These programs are completely optional, they are just for 3D creating objects to print. You can use a website such as Thingiverse to fin files other people have designed.

This concludes the Basics of 3D printing. Come back next week for a new post! Posts go up Friday Afternoons.

Thursday, September 15, 2016

Welcome to Will's Movie Replicas!

Hi! my name is Will, and this is my costume and prop blog. My favorite hobby is looking at props and costumes from movies, and bringing them to life! This blog is out here for you to enjoy and for help if you want to try building something on your own. As of September 15, I have 5 main Build projects. These are just images for reference, not what I have done.

Robotic BB-8 Build with a LEGO Robotics Kit

 Image result for BB8
Iron Man Mk 6 Cosplay (with electronics)

Image result for Iron man mk 6

3-D Printed Captain America Shield Clock
Image result for captain america shield

3-D Printing Tips and Tricks
Image result for alunar m505

1 Meter Tall Papercraft Hulkbuster Statue

Image result for Hulkbuster

So, as you can see, I have a lot of things planned on this blog already, and this is my first post! I hope you enjoy WMR Studios!