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Starcraft 2 Marine Armor
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TK 109
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Joined: 11 May 2007
Posts: 712
Location: Galena, Ohio

PostPosted: Mon Aug 27, 2007 1:06 pm    Post subject: Reply with quote

nifty!

this is gonna be pretty cool!

i'm sure this isn't cheap? i mean, it actually sounds like i good idea for mold-making for stormtrooper armor, ect. as well. i'm sure plaster would work just as well for stormtrooper armor, though. that is, making a mold out of dense foam, or clay, and take a cast of that and a cast of the negative out of plaster.....
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vrogy
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Joined: 31 Jul 2007
Posts: 22
Location: in Sunny Florida!

PostPosted: Tue Sep 04, 2007 2:22 pm    Post subject: sharp LFMC Reply with quote

If you've been following along, you'll probably notice that last time I had the lost foam process working, but the edges of the cast part were rough.

Well, we've solved most of that.



Basically, we used a technique known as 'investment' to coat the foam with a high-quality finish that won't melt- in this case, ground drywall and clay.



The results still aren't flawless, and need finishing, but they're a lot better.



You can see here that most of the flaws on the V are how I cut it- by hand. Next time I guess I'll use an endmill in the drill press like the decepticon casting was done.



Another issue that's popped up is the porosity seen in the decepticon casting- I asked around on some casting forums, and apparently it's from gas bubbles forming in the melt, from impurities(mostly hydrogen). A quick solution is apparently to bubble argon through the molten aluminum, which is easy enough to do.

I've been plugging away at the CAD still, it looks like the first actual suit pieces we cast will either be some of the C.M.C.-400 boot fittings, or parts for the C-14 Impaler gauss rifle.
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vrogy
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Joined: 31 Jul 2007
Posts: 22
Location: in Sunny Florida!

PostPosted: Mon Oct 08, 2007 11:23 pm    Post subject: Reply with quote

Oh wow, looks like I forgot to post updates here.. Rolling Eyes

Well, let's see...

-got a site: http://vrogy.net/

-started on a CNC machine to cut all the special foam pieces on for casting.
these guts: http://www.hobbycnc.com/4aupc.php
these plans: http://rockcliffmachine.com/pictures.htm

motors, driver board kit

driver board assembled

power supply for the machine

-Progress on the gauss rifle CAD. I need something to motivate me on this.

Solidworks model

one of my reference images

-figured out how to hinge to suit, and if I'd fit.



From here:
-finish CNC machine
-finish gauss rifle CAD
-cast and assemble gauss rifle
-work on armor articulation prototype- wood 1X2 & plastic exoskeleton to test hinging theories.
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CJanssen
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Joined: 17 Feb 2007
Posts: 215
Location: Beaverton OR

PostPosted: Mon Oct 08, 2007 11:31 pm    Post subject: Reply with quote

Looks like great progress...keep up the good work. That suit is going to be awesome.

CJ
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TK 109
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Joined: 11 May 2007
Posts: 712
Location: Galena, Ohio

PostPosted: Tue Oct 09, 2007 1:59 pm    Post subject: Reply with quote

...

Shocked

...

um...

Shocked

...

NICE!! Wink
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jegner
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Joined: 30 May 2003
Posts: 2144
Location: Texas, USA

PostPosted: Tue Oct 09, 2007 2:35 pm    Post subject: Reply with quote

Oh, my!

Looking good! Are you going to CNC the suit?
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vrogy
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Joined: 31 Jul 2007
Posts: 22
Location: in Sunny Florida!

PostPosted: Tue Oct 09, 2007 4:22 pm    Post subject: Reply with quote

jegner wrote:
Oh, my!

Looking good! Are you going to CNC the suit?


Heh, thanks. I am indeed planning upon CNCing it, in an indirect way.
Basically, the idea is to CNC layered MDF molds for the vacuum-formed stuff, and foam for the lost-foam-metal-cast parts.

If you slow the cinematic Blizzard released down and take screenshots

You can see that the way it's made is with a frame that's bolted and welded together, which contains all the joints and hinges, and armor plates fastened on top.
Basically, the plan is to replicate that, using cast aluminum pieces bolted together for the frame, and vacuformed plates over the top which are mostly bolted in place.
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vrogy
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Joined: 31 Jul 2007
Posts: 22
Location: in Sunny Florida!

PostPosted: Fri Jan 30, 2009 6:49 am    Post subject: Reply with quote

I've since..

-started a CAD model




-finished a CNC machine




pending are a finished CAD model and a more accurate CNC machine, possibly with a larger capacity- this one's limited to about 8X10X3"
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jegner
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Posts: 2144
Location: Texas, USA

PostPosted: Fri Jan 30, 2009 7:21 am    Post subject: Reply with quote

Awesome update! Wow! Great progress.

Jim
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vrogy
Newbie


Joined: 31 Jul 2007
Posts: 22
Location: in Sunny Florida!

PostPosted: Wed Feb 04, 2009 9:06 pm    Post subject: Reply with quote

Just finished a CNC upgrade; from 1/4-20 threaded rod leadscrews to 1/2-10 acme leadscrews.

This allowed me to eliminate a whole bunch of backlash from the machine, and almost double travel speeds. Maybe I can get parts under 5 hours now..
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thomas bas



Joined: 22 Aug 2010
Posts: 2

PostPosted: Sun Aug 22, 2010 11:06 am    Post subject: Reply with quote

that's a coincidence: i'm just getting started on warhammer 40k armour. Starcraft is based on it, so I could learn a thing or two from you, eh?
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croky_b
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Joined: 29 Dec 2009
Posts: 44

PostPosted: Mon Aug 30, 2010 1:35 pm    Post subject: Reply with quote

thomas bas wrote:
that's a coincidence: i'm just getting started on warhammer 40k armour. Starcraft is based on it, so I could learn a thing or two from you, eh?

a double coincidence i'm just finish my W40K helmet
http://www.tk560.com/phpBB2/viewtopic.php?t=1581
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Benjaminvegeta
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Joined: 21 Feb 2010
Posts: 36
Location: Bavaria/Germany

PostPosted: Mon Aug 30, 2010 2:59 pm    Post subject: Reply with quote

Won´t the suit be extreme heavy in the end, if you build an aluminium exoskeleton?
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