War-Machine MkIII Aluminum armor WIP

[War-Machine]

This will be an all aluminum build with programmable micro controllers that will operate servos, sound, led's. For the weapons, faceplate ect. I'll be using 0.063-5052 aluminum sheet. This will be an armor that i can wear at Comicons, charity events ect. Most of all i just want to see if i can pull it off...GM

[stevec]

(02-18-2015, 04:23 PM)EdK Wrote: So are you actually going to build your version of it out of metal or are you just drawing it up for the hell of it?  

Ed

Thanks Ed and Darren, I'm not the only one puzzled about something I may well not care about.

Steve

[War-Machine]

(02-18-2015, 06:34 PM)stevec Wrote:

(02-18-2015, 04:23 PM)EdK Wrote: So are you actually going to build your version of it out of metal or are you just drawing it up for the hell of it?  

Ed

Thanks Ed and Darren, I'm not the only one puzzled about something I may well not care about.

Steve

Yes, it is my intent to recreate the Mk-I a redesign...GM

[War-Machine]

These are the drawings that i made up, they were sent to a modeler and from there to a printer.


Now this had arrived a couple of weeks back. I had mended them together. More pics to follow...GM

[War-Machine]

So i mended the helmet with aluminum screen using a soldering iron.

Back profile.


Now this is the 3d printed helmet. Now i intended to clean this up and cast it in a resin. But the more i look at it, the more i know that it has to be metal. The eyes will be lit with leds until the faceplate lifts. The jaw at the same time will thrust foward. I just ordered some aluminum bar for the hands.

This is a hand file for pepakura

This is the glove or hand of the Iron-man Mk-V. All the hands are universal for most of the armors...GM

[War-Machine]

Ok folks i'm going to need some input from ya. This is a 1 1/2 inch diameter 6061 aluminum. Now the cardboard piece next to it is a tip of a thumb as a reference. Now i thought that i would use a drill press to begin drilling the cavity. The thumb however is not a perfect circle so i was thinking that i would use a dremel to bore out the shape using a carbide burr. Once that is done, i would then form the outer diameter to the desired shape. So i'm asking you the pro's, does this sound viable or do you have a better idea? Thanx in advance...GM

[TomG]

That is WAY too much shaping for a Dremel. You are going to have to invest in either a die grinder or a Foredom flexible shaft grinder. Even so, you'll need to remove as much material as possible with a band saw.

Have you thought of using fiberglass for those parts? Make a clay model of the part and use that to make a silicone mold. Then just lay the fiberglass up in the mold. You could include metal inserts for fasteners or high strength areas. The molds can be used to make multiple parts.

Tom

[War-Machine]

(02-25-2015, 08:03 PM)TomG Wrote: That is WAY too much shaping for a Dremel. You are going to have to invest in either a die grinder or a Foredom flexible shaft grinder. Even so, you'll need to remove as much material as possible with a band saw.

Have you thought of using fiberglass for those parts? Make a clay model of the part and use that to make a silicone mold. Then just lay the fiberglass up in the mold. You could include metal inserts for fasteners or high strength areas. The molds can be used to make multiple parts.

Tom

Hey Tom thanx for getting back to me on this. Fiberglass is not an option for me on this. I am very familiar with using fiberglass as i have made 5 helmets with it. Can you recommend a die grinder? The Foredom flex shaft is between 60-90,000 rpm's and has a pedal to operate. Is this what you are mentioning? Thanx again for the tip...GM

[War-Machine]

A quick correction from previous post. The RPM's are around 18,000. I have access to a die grinder so this weekend i'll give it a go and see what happens...GM

[TomG]

The Foredom would be perfect for this application because hand carving is what they were designed for, but they are expensive. A cheaper alternative would be a pneumatic die grinder that would accept burrs with 1/4 shanks, assuming you have air.

Tom