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MDF Endor Commando Donut mold

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

PostPosted: Wed Jun 13, 2007 6:26 am    Post subject: MDF Endor Commando Donut mold Reply with quote

Well, a new mold is currently being made for the Endor Commando Donut.

This project is taking longer than expected, but here's what I learned:

Making two molds that clam-shell together, for a tight fit is tricky. I suppose industrial fabications use CNC to ensure the proper fit. Me, I had to make the top part of the donut first, and get a working mold, then pull a part, and start making the mold that will fit into it tightly. Below are some pics of the project:












the bottom mold.

These last two are upside down

and the grouping of molds for the donut, so far.
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tubachris85x
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Joined: 15 Jan 2007
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Location: Ft. Lauderdale, Florida

PostPosted: Wed Jun 13, 2007 10:33 am    Post subject: Reply with quote

Looks like your doing a good job there. Is that white piece a vacu-formed half of the helmet?

-tubachris
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jegner
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Joined: 30 May 2003
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PostPosted: Wed Jun 13, 2007 10:49 am    Post subject: Reply with quote

Yes!
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Solo
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Joined: 31 May 2007
Posts: 35
Location: New Jersey

PostPosted: Wed Jun 13, 2007 1:21 pm    Post subject: Reply with quote

It looks great, do only glue the MDF board together or do you nail the inside portions with a brad nailer to help hold it all together?
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jegner
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PostPosted: Wed Jun 13, 2007 1:33 pm    Post subject: Reply with quote

Glue only.
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Solo
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PostPosted: Thu Jun 14, 2007 5:53 am    Post subject: Reply with quote

Do you use regular carpenter glue?
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jegner
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Joined: 30 May 2003
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Location: Texas, USA

PostPosted: Thu Jun 14, 2007 6:26 am    Post subject: Reply with quote

Yes, the Titebond II from Lowes. Smear it on, let it dry, and you are good to go.

Jim
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Solo
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Location: New Jersey

PostPosted: Thu Jun 14, 2007 7:34 am    Post subject: Reply with quote

Thanks

Everyone here has been real helpful. I am hoping to get started with everything this weekend. I actually have some MDF laying around and I want to dive into the mold making since it appears to be the most time consuming.

Mike
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badger
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Joined: 03 Sep 2006
Posts: 63

PostPosted: Fri Jun 15, 2007 2:02 am    Post subject: Reply with quote

I know they're really looking forward to the mold. Smile

It's looking good.

I need to go buy some MDF and get cracking on the first pieces for my next project, it's going to take a while. I'm always impressed with what you pull out of flat pieces, Jim, you are an inspiration.

badger
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jegner
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PostPosted: Fri Jun 15, 2007 6:20 am    Post subject: Reply with quote

Thanks Badger! Do, pray tell, what are you working on next?

Jim

BTW, how did you end up fitting your x-wing visors to your helmets?

Jim
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jegner
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PostPosted: Wed Jul 18, 2007 12:55 pm    Post subject: Reply with quote

Here is another pic, for the donut ready for a top coat:


and it mounted on an AN-H-15 flight cap:
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