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NuggetWarmer
June 17th, 2009, 12:54 PM
As quoted from my partner in the project, Yodajammies:

Well, I teased at it a couple months ago, but here it is. The progress thread for the first suit of armor robotically milled on a CNC table, and then molded and cast as per traditional methods.

Huge props go out to Nugget for his phenomenal speed and skill in 3d modeling. This project could have never succeeded without his expertise and knowledge. Minor shoutouts go to Vrogy for his CNC advising at the shop, and general all around snarkiness. (I hear he is milling a marine suit. oh exciting!)

Being a WIP thread, I figure I'll cover the basic process and procedure for anyone looking to explore this method of armor building.

D'con is right around the corner, so I'll be spending an inordinate amount of time in the shop trying to get this done. My hope is that I can pull several full suit casts for trade at the con. (I'm looking at you Adam. I want one of those assualt rifles)

Alright! Lets get started -

First, our own resident modeling virtuoso Nugget builds the 3d file which will get interpreted into G-code for the ShopBot CNC.
http://i4.photobucket.com/albums/y122/Yodajammies/maxShot.jpg
Next I take the 3d data and use it to develop G-code that the CNC actually uses to cut the part.

http://i4.photobucket.com/albums/y122/Yodajammies/cut3dPreview.jpg
So then we get to the actual milling!

My new favorite shop toy (can you guess what it's cutting?)

http://i4.photobucket.com/albums/y122/Yodajammies/100_4125.jpg
For this project I used MDF as my milling material. It can't hold nearly the detail I imagined it could, but it cheap and abundant. Later down the line I may take a page out of Legendary Armor's book and use a high density urethane foam for milling. I've played around with a couple samples of it, and although the stuff is 4-5 times the price of MDF board, the resolution capable of being captured on the first past is fantastic.

So now we have a wooden master which looks a little something like this. The top cut is using a 11% stepover on the finishing path, whereas the bottom is stepping over 20%. You can see how much of a difference this makes to the finish of the final piece.
http://i4.photobucket.com/albums/y122/Yodajammies/100_4117.jpg
Now we go about making a "scrap mold" of this piece to produce a plastic copy for clean up. This is the extra step required to achieve the level of detail we can't get by using MDF. After sealing, priming, molding, casting, and doing a bit of clean up, we come to the final, moldable master. (please excuse the crappy cellphone image)

http://i4.photobucket.com/albums/y122/Yodajammies/IMG00024.jpg

Now we are ready to mold the final piece and start production of these high quality handplates. Take a look at the differences between the preliminary mdf cut and the sanded secondary. It could use a little more TLC, but my production schedule is tight and I need to keep the ball rolling.
http://i4.photobucket.com/albums/y122/Yodajammies/DSC00768.jpg
http://i4.photobucket.com/albums/y122/Yodajammies/DSC00769.jpg
And now we come to painting and detailing. The plates first recieve a nice heavy coat of primer. I cannot stress enough how critical primer is to achieving a stellar paintjob on your armor. Next I laid down a coat of brushed steel. I'm going with a Colonial Red in honor of my alma mater - North Carolina State University. Go wolf pack. Yadda yadda yadda. I believe it was Thorisill who introduced the "Condiment Painting" technique here on the boards, and I decided to give it a test run on a pair of plates. I decided to go with a nice Kraft Ranch here, and I the results turned out quite nicely, or at least passable for the first attempt.

http://i4.photobucket.com/albums/y122/Yodajammies/DSC00779.jpg
http://i4.photobucket.com/albums/y122/Yodajammies/DSC00783.jpg
http://i4.photobucket.com/albums/y122/Yodajammies/DSC00786.jpg
http://i4.photobucket.com/albums/y122/Yodajammies/DSC00787.jpg

http://i4.photobucket.com/albums/y122/Yodajammies/DSC00789.jpg
Finally, I'm using a basic black acrylic to add some filth to the final piece. Similar to the "panty hose and black spraypaint technique", but I've found that acrylic is a little easier to work with, and to edit in case you make a mistake or change your mind about how you want the final piece to look. I am no painter, and my technique is still fledgling, but I can see the potential for a fairly nice paintjob in this method. By the time I get to the final piece of the suit, I should have it down pat.

http://i4.photobucket.com/albums/y122/Yodajammies/DSC00794.jpg
http://i4.photobucket.com/albums/y122/Yodajammies/DSC00795.jpg

Now of course I haven't just finished one measly piece in 3 months. There are many irons in the fire, but I can tease with a couple other parts I have been chipping away at. Here is a prototype arm piece, the preliminary cod (or penis plate as Nugget calls it), and a test cut BR. Enjoy!

http://i4.photobucket.com/albums/y122/Yodajammies/IMG00021.jpg
http://i4.photobucket.com/albums/y122/Yodajammies/MKVI_forearm_bamf.png

http://i4.photobucket.com/albums/y122/Yodajammies/IMG00029.jpg

http://i4.photobucket.com/albums/y122/Yodajammies/100_4136.jpg

Feel free to post any questions or comments here. :)
Rentafence
June 17th, 2009, 12:59 PM
Do this:

1 Buy a 100$ WE 1911 airsoft pistol

2 Take out the internals

3 Model the slide, frame etc for the Magnum so that it fits to the internals.

4 Magnum airsoft gun!
Masterz1337
June 17th, 2009, 12:59 PM
This is pretty damn cool.
klange
June 17th, 2009, 12:59 PM
Awesome.
Heathen
June 17th, 2009, 01:15 PM
so, legit armor?
NuggetWarmer
June 17th, 2009, 01:24 PM
Pretty much. It's not sponsored by MS or Bungie though.
Heathen
June 17th, 2009, 02:13 PM
gangster
MetKiller Joe
June 17th, 2009, 02:25 PM
Nice. Very nice.
Hotrod
June 17th, 2009, 03:14 PM
Wow, I've always wanted to do something like that, but unfortunately never had the means to do so. :(

This looks badass though, can't wait to see it completed!
Sel
June 17th, 2009, 03:16 PM
cardboard YEHH
klange
June 17th, 2009, 03:32 PM
cardboard YEHH
It's plastic. Cardboard is used to make a rough.
English Mobster
June 17th, 2009, 03:42 PM
Fuck yes.

I agree with the airsoft gun idea. While you're at it, make an airsoft BR.
NuggetWarmer
June 23rd, 2009, 06:09 AM
Just a pictureless update here:

Yodajammies forgot to close the lid all the way on our molding equipment (dragonskin), so it was left open for about six days before anyone noticed. Since it's so hard to get it to cure now, we're moving over to box molds.

Model wise, I still have to finish the helmet, thigh pieces, and shoulders, then I can begin props to go with it.
English Mobster
June 23rd, 2009, 07:29 AM
That is fucking awesome.
Keep 'er updated.
Encoded
June 23rd, 2009, 08:00 AM
I would like to acquire one of those suits.

Too bad I have no money, nor the means to make one.
neuro
June 23rd, 2009, 09:24 AM
this looks coool.
mR_r0b0to
June 24th, 2009, 04:59 AM
:3 i wanted to do this but the cnc mill at school is so tiny it's useless
Warsaw
June 24th, 2009, 09:44 PM
Next stop: aluminum. =D

This is awesome, can't wait to see the finished product. As for rifle, might I suggest an airsoft FAMAS with some very heavy modification to make it either an MA5C or BR55?
Sever
June 24th, 2009, 09:55 PM
As for rifle, might I suggest an airsoft FAMAS with some very heavy modification to make it either an MA5C or BR55?Or you could be not a fanboy cool and do something like a Carbine.
sdavis117
June 24th, 2009, 11:42 PM
I'd take one, as long as it had a larger cod piece.

Nice work there. Better then all these cardboard cut outs I've been seeing on the web.
Heathen
June 25th, 2009, 12:59 AM
Why not make it Ceramic?
Warsaw
June 25th, 2009, 02:01 AM
Or you could be not a fanboy cool and do something like a Carbine.

It's for ease of modification while retaining functionality. Personally, I despise the BR55 and MA5B/C completely and would rather go with an M7, but hey, to each his own.

Also Heathen, ceramics are extremely hard, but also extremely brittle. It doesn't take much to shatter, split, crack, or otherwise break them.
n00b1n8R
June 25th, 2009, 02:03 AM
Because that is difficult as fuck?

Or you could be not a fanboy cool and do something like a Carbine.
Ah yes, glowing green projectiles are easy to come by :downs:
Make an needler. http://sa.tweek.us/emots/images/emot-q.gif
HDoan
June 25th, 2009, 02:08 AM
Because that is difficult as fuck?

Ah yes, glowing green projectiles are easy to come by :downs:
Make an needler. http://sa.tweek.us/emots/images/emot-q.gif
Ah yes, glowing pink projectiles that home into targets are easy to come by:downs:
Warsaw
June 25th, 2009, 02:09 AM
Shotgun.

Or you could buy this. (http://www.boomingisland.com/showproduct.aspx?ProductID=630&SEName=halo-3-covenant-energy-sword-fx-replica-master-replica)
NuggetWarmer
June 25th, 2009, 02:12 AM
We have a carbine, a br, and a shotgun in the works. Along with some nades (plasma and frag) too.


E: A needler would be badass. I'll talk to Yoda about it. Thanks n00b.
rossmum
June 25th, 2009, 02:13 AM
Ah yes, glowing pink projectiles that home into targets are easy to come by:downs:
who said it had to fire actual pink homing needles

the loaded ones are piss easy, just put some leds inside it and use some kind of pink or purple crystal for the needles
Cortexian
June 25th, 2009, 05:18 AM
I will send you the "ATTN: FREELANCER STOP POSTING - MODACITY" sign for a full size Halo 1 AR (painted and everythan').

DEAL OR NO DEAL!?
NuggetWarmer
June 25th, 2009, 04:30 PM
no :c
sdavis117
June 25th, 2009, 05:21 PM
I'll take the sign.
jngrow
June 25th, 2009, 06:40 PM
Ah yes, glowing pink projectiles that home into targets are easy to come by:downs:

Irony
paladin
June 25th, 2009, 06:52 PM
Shotgun.

Or you could buy this. (http://www.boomingisland.com/showproduct.aspx?ProductID=630&SEName=halo-3-covenant-energy-sword-fx-replica-master-replica)


I have two
NuggetWarmer
July 18th, 2009, 02:15 AM
Since Yoda is bad about taking pics, Vrogy took some and sent them to me today. :)

http://farm3.static.flickr.com/2509/3718432249_e99771e9a1_b.jpg
http://farm4.static.flickr.com/3510/3718431567_fbfba4327f_b.jpg
Heathen
July 18th, 2009, 02:59 AM
What's the bottom one?
ThePlague
July 18th, 2009, 03:00 AM
Ass plate.
n00b1n8R
July 18th, 2009, 03:03 AM
I think it's the backplate.
Limited
July 18th, 2009, 03:16 AM
Damn that's sick can't wait to see the final product.
NuggetWarmer
July 18th, 2009, 06:06 AM
Ass plate.

He's got the right idea.
legionaire45
July 18th, 2009, 12:42 PM
Make a recon version.
Advancebo
July 18th, 2009, 01:02 PM
No Mark V.
DrunkenSamus
July 18th, 2009, 01:04 PM
I thought this thread was about a Halo mod for Command & Conquer. :(
ThePlague
July 18th, 2009, 02:12 PM
You all fail, do ODST
NuggetWarmer
July 28th, 2009, 04:05 AM
http://i4.photobucket.com/albums/y122/Yodajammies/DSCN1289.jpg

Front chestplate almost ready to be molded.
ThePlague
July 28th, 2009, 04:08 AM
:D
TomClancy
July 29th, 2009, 02:04 AM
Looks awesome, nice stuff.
NuggetWarmer
August 18th, 2009, 12:36 AM
Almost done. Won't get the helmet done in time for Dragon Con, so we bought one from a friend for the time being.

http://i4.photobucket.com/albums/y122/Yodajammies/100_4165.jpg
Yoda wearing temp helmet. kinda :(
http://i4.photobucket.com/albums/y122/Yodajammies/100_4183.jpg
http://i4.photobucket.com/albums/y122/Yodajammies/100_4182.jpg?t=1250569310
http://i4.photobucket.com/albums/y122/Yodajammies/100_4151.jpg?t=1250569326
another angle of the chestpiece
http://i4.photobucket.com/albums/y122/Yodajammies/DSCN1290.jpg?t=1250569336
kid908
August 18th, 2009, 12:53 AM
Everything look nice but I don't like the helm for some reason.
NuggetWarmer
August 18th, 2009, 12:56 AM
Learn to read. c:
kid908
August 18th, 2009, 12:59 AM
I know you bought it. I'm just saying it looks extremely odd to me.
legionaire45
August 18th, 2009, 01:15 AM
Perhaps the fact that it is sitting on realistically sized person's head, not a 7 foot tall Spartan with full armor?
n00b1n8R
August 18th, 2009, 02:36 AM
How much was the helmet, how much would it cost for me to get you to make me a suit?
NuggetWarmer
August 18th, 2009, 04:00 AM
If you go by the pepakura method, it's a lot cheaper/easier. I suggest you check out the forums at www.405th.com. The registration might be closed, but I'll talk to the owner about letting you in. :)

The helmet was a good price, but I'm not positive on how much it actually was. I'll ask Yoda about it.
Advancebo
August 18th, 2009, 05:59 AM
I know you bought it. I'm just saying it looks extremely odd to me.

Because you dont want to see whats under it :ugh:
SonicXtreme
August 18th, 2009, 06:32 AM
The reason why its wierd , if you compare it to the Halo 3 Limited Edition Helmet is because ...

1: The mouth section is too wide vertically , thus making the visor look tiny

2: The black parts that the visor clips into at the side of the helm are missing

3: The sides of the helm are too far out

In short , its out of proportion radically and therefore looks :/
Heathen
August 18th, 2009, 08:03 AM
Because you dont want to see whats under it :ugh:

http://www.modacity.net/forums/images/customavatars/avatar2484_8.gif
Rob Oplawar
August 18th, 2009, 05:17 PM
For future reference, when discussing armor, Helm =/= Helmet, guys.
e: fuck, yes it is, I'm retard. What was I confusing it with? For some reason I thought helm was a type of handpiece. Don't listen to me, guys.
Ganon
August 18th, 2009, 05:41 PM
For future reference, when discussing armor, Helm =/= Helmet, guys.
e: fuck, yes it is, I'm retard. What was I confusing it with? For some reason I thought helm was a type of handpiece. Don't listen to me, guys.

usually if two words are that similar, chances are they are closely related or are the same thing... i mean come on, helm and helmet lol

This project looks neat though, can't say I'd be caught dead doing cosplay though!
paladin
August 18th, 2009, 09:39 PM
Im jealous.
NuggetWarmer
August 19th, 2009, 09:54 PM
http://i4.photobucket.com/albums/y122/Yodajammies/100_4187.jpg

e: that's Yoda.
paladin
August 19th, 2009, 10:04 PM
Forearms look way too big but then again, youre no Master Chief :)
ThePlague
August 19th, 2009, 11:12 PM
:o :awesome:
Hotrod
August 20th, 2009, 10:31 AM
Damn, that looks pretty awesome so far, except the helmet you showed there isn't all that amazing. The piece that covers the mouth is way too big, and the visor is too small. But it's not the helmet you're making, so it's not you that I should be complaining to. :)
n00b1n8R
August 21st, 2009, 01:12 AM
Too shiny, otherwise great.
ThePlague
August 21st, 2009, 01:20 AM
What kind of fabric are you using for the suit?
NuggetWarmer
August 21st, 2009, 02:45 AM
We're not sure if we're going with accurate underarmor, or just sticking with a basic undersuit.
Cortexian
August 21st, 2009, 03:16 AM
The underarmor is what makes the good halo armors look great tbh.
ExAm
August 21st, 2009, 06:21 PM
Forearms look way too big but then again, youre no Master Chief :)
Ever noticed how badly proportioned the Master Chief really is?