2024 Monthly Build Projects

[Fallen]

This will be encompassing projects in various areas include costume updates, props, woodworking, and home so Off-Topic makes the most sense.

Back in December I decided to make a goal for myself that I wanted to attempt to finish 1 small project per month this year. I have no idea what all of the projects are, but I had a rough idea of things that I wanted to accomplish in 2024.

Goals:
- Finish props that have been sitting in my "pile of shame"
- Update my Mk VII before HCS Seattle
- Finish my garage shop
- Stretch Goal: replace flooring on main level of house

As it's already March, and I didn't decide to make this thread until now, this first post will go ahead and cover January and February's projects and lay out the plans for March, April, and possibly May.

January
January's project was a pre-requisite in my mind to my garage shop. I have a bunch of leftover lumber and plywood from projects I've worked on in the past couple of years that I wanted to get up off the floor and make more easily moveable around the garage for while I'm working on things like electrical and drywall. Lumber cart it was. Made a quick mockup of the original plan using mostly materials I had leftover or had bought for projects I no longer intend to do, adjusted for my needs, and got to work.

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By the end of the month I had it functional sitting on 6 casters and loaded up w/ any materials I had lying around. Best part was getting old plywood moved off the back wall of my garage where I plan to be running 4 outlets for some workbench spaces. I do plan to paint it if for no other reason than I like to walk into my working spaces and not get overstimulated by visual clutter, but for now it's functional and that's enough.

February
This one was a prop to knock off the list. A long while ago I'd printed TurboCharizard's Skewer model at 83% scale, and I was finally going to finish it. For fun I opted to go with the Volatile Skewer as my color scheme just 'cause. I did end up doing some reprints because I'd gotten a better printer since my original batch that worked better for tolerances. One thing I also experimented with was the idea of using flexible filament for the knife and possibly the dart (more on that later).

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For ease I sanded each part separately first to 120 grit before assembling, filling, and the sand, prime, repeat dance before paint.

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Even at 83% this thing is big, coming up to about my shoulders w/ the blade affixed.

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One of the last steps was dealing with the dart. First attempt I printed entirely in flex PLA like the knife blade but decided to try my hand at casting it, so using Orcaslicer I was able to create a mold of the top of the dart and slice the mold with registration points. I printed it at .08mm layer heights and didn't bother to sand down the layer lines as I wasn't sure if it'd even work as planned. Using some armature wire for stability and black and metallic blue mica powder to tint my silicone I made my first attempt at moulding the dart. I printed the main body of the dart in flex pla and adjusting the model (again in Orcaslicer) to have a cap on the top that I could glue the silicone top to using a silicone adhesive. Ultimately I did end up re-doing the dart, and I'll probably do so one more time before C2E2.

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Prior to Planet Comicon I did some simple weathering with just some oil paints. I still want to go back and do some silver and edge weathering, but that'll be either right before or while I'm at C2E2 as I don't have it back home with me at this time.

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Since I only suited up for maybe an hour on Friday at Planet and was in my H3 Marine setup, I didn't make sure to grab any shots of me with it, but I did grab a fair number of pics of other members holding the Skewer. Hopefully with some Mk VII updates happening prior to C2E2 I'll be able to get the photos I want there. Here's some of the photos I grabbed at Planet of others though.

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Tentative Plans

• March​
  • Mk VII updates for C2E2​
    • Upscaled Mk VII helmet to account for audio system - Construction Complete​
    • Turbo's Mk VII Chest and Back printed to replace parts used for Peppermint Laughter - Construction Complete​
    • New boots using the same method I did for Peppermint - Construction Complete​
  • Garage​
    • Remove anything remaining on walls from previous owners - Complete​
    • Start running electrical - Delayed to April​
    • Hire company to install door to backyard - Delayed​
• April​
  • Mk VII updates for C2E2 Continued​
    • Seal and paint​
    • Update electronics​
  • C2E2 Flagpoles (2)​
  • Garage​
    • Run electrical​
• May​
  • Garage​
    • Order Drywall​
    • Insulation​
    • Install mini-split - Delayed​

 

[Fallen]

March is over, so what got completed? What's in the works? What's been pushed off?

Mk VII

• 3D Printed Parts - printed, sanded, and primed
• Boots - foam construction, seams filled, sealed
• Partially through paint
• Materials purchased for electronics

Garage

• Delayed in general due to logistics with helpers
• Getting some bids on door installation because that's a job I don't enjoy doing

Anything else?
Closer to the end of the month I started a couple of things for C2E2 that I didn't list in my project list, 2 flagpoles and 2 new helmet stands (tutorial and files coming soon). I still need to do the tall parts for the flagpoles, and I'll wait until I post the tutorial for any helmet stand photos.


The framing of this wasn't planned that way, but I kind of like how it looks like the skulls have horns.

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So based on what got done in March how does the plan change for April and May?

• April
  • Mk VII updates for C2E2 Continued
    • Seal and paint
    • Update electronics
  • C2E2 Flagpoles (2)
  • Helmet Stands (2)
• May
  • Garage
    • Electrical
    • Insulation - stretch goal
  • Prop
    • Either Plasma Rifle or Grenade Launcher - sand and prime

 

[Fallen]

April's Update

Managed to get everything on the must-do list completed in time before C2E2. Updates to my Mk VII were completed and are documented in greater detail in my build thread.


Flagpoles and helmet stands also got completed with some adjustments to any models I made for the helmet stands being updated throughout and after the build. I plan to make 2 more helmet stands with the updated models and then can get everything out there with a tutorial thread for anyone who wants them.



So what about May's plans. First up is something that's a bit out my control for timing. I've reached out to my electrician family member, and we're figuring out when he can come and a) help me plan out electrical for my garage and b) run anything that needs to be done. I know I want to be adding about 5-6 new outlets 4 of them being in double boxes where my primary workbench will go and 1 or 2 near the front of the garage for easy access out front. What I more want his help in is planning the lights so I have plenty of lighting to work and running what I need for a ductless mini-split AC and heat pump. Hoping he's available soon to get to the point I can be insulating and drywalling at least the walls. That mini-split will be a game changer for moving my shop into the garage where it belongs.

I'm not sure if I'm going to do a prop build this month or take a break. I may just get a list of any repairs on my suit and make those for TremendiCon at the end of the month. If I do a prop build I'm thinking of finishing my grenade launcher and maybe in June starting a stand for my Mk VII suit.

I will be starting some of the planned updates for my Mk VII that I want in time for HCS Worlds in October, but as I don't need to finish them in a given month yet, they aren't part of my monthly projects right now.

 

[Fallen]

A little late, but May update time.

Not much to show for this month's projects. I doubt you all want to see dirty to clean house pics. Yeah this month's project was decluttering and cleaning the house. I probably could have been even more brutal in my selections of donate and trash items, but the next pass will be easier now that this one has been done.

The other things that happened were planning of projects. Met with my electrician to talk about my goals for my garage project and figure out lighting plans, outlet placements, and my temperature situation. Things are planned, first phase purchased, and wire has been run but waiting for electrician to come hook things up before phase 2. Also planned out a woodworking project for a temporary wall that'll be on wheels for my basement with internal storage. Chose wheels so I can move it around to where it's most useful at the time, framing like a normal wall to make mounting things to the wall simpler if I so desire, and made it deeper than a normal wall to be able to use it for storage for long, somewhat skinny items like lighting stands, the pvc pipes for my pop-up paint booth, etc.

June Plans
- Halo Reach Grenade Launcher - prepped for paint
- Print TPU parts for updating my Mk VII
- Fix the Skewer - repair cracks
- Storage wall on wheels - construction
- Finish electrical (?) - dependent on electrician

Nothing has to be fully finished in the 3 remaining weeks, but I want anything requiring printing and/or sanding to be ready for paint by the end of the month. Storage wall I want constructed but not necessarily taped and mudded and ready for primer. Electrical takes the highest priority though, so if my electrician gets his part done and I have an assistant for the other phase anything else can be shelved for finishing electrical. Really hoping to be doing insulation and drywall next month.

 

[Fallen]

Another month another set of projects. Unfortunately none of them got fully finished this month, but a few things made good progress.

• Grenade Launcher - still sitting on my dining room table calling for me to get to work
• TPU parts for Mk VII - 1 part finished then repurposed printers for a different project
• 
  
• Fix the Skewer - yeah, no progress here. I know I need to just do it
• Storage wall on wheels - frame built, drywall on both sides, and 1st side mudded, taped, and primed
  • This is where the printers got repurposed because I got an idea and ended up printing a bunch of panels for it
• Finish electrical
  • electrician finally got over here and installed the auxiliary panel in the garage
  • next step is running everything for outlets and lights in the garage itself

Let's talk that wall. This is a multi-purpose project w/ a deadline near the end of the month. With members coming over and doing a couple of photoshoots both indoors and out I wanted something I could use as an interesting backdrop that would take various lighting setups well. I came across these hexagon sound diffusion panels that I thought would look pretty cool and decided 1 side of the wall will get that and the other will be a dark gray or black.

I took apart 2 walls on wheels I'd done a year or two ago and rebuilt the frame into 1 wall. After its first purpose it will become a moveable divider wall in the basement.

A look at the panels and how they look w/ a couple of lights. I ended up printing a little under 100 full size panels and still need to figure out placement and then slice up the model for various partials to complete the wall. That'll come after I finish priming both sides.

 

[Fallen]

July builds

Projects listed at the beginning of the month:
- Grenade Launcher - no progress; others came first
- Mk VII TPU parts - ready for paint
- Fix Skewer - cracks repairs, needs sanding and paint touch-ups
- Wall on Wheels - Finished
- Electrical - rolled over

My primary goal was that wall on wheels that I wanted done before people showed up for a photoshoot here. We used the hexagon side of the wall for photos for a few people, and now it's moving to its semi-permanent location as a moveable storage wall for some of my gym equipment, things like bands and other lightweight pieces.

Pics of the wall throughout the build and what it looked like in portraits.


Bonus Projects:
- Started on my next armor build - no deadline
- Started on my Secret Santa project



Finally found a use for some of my old PLA I don't entirely care for; supports for TPU prints.

August Plans:
- Garage - finish electrical and insulate, drywall is a stretch goal
- Keep printing rakshasa parts
- Finish printing Secret Santa parts
- More Mk VII updates - sand new forearms, finish the tpu parts, maybe ab wrap

 

[Fallen]

Well look at that another month passes. We're now in the point where some of the projects I've been working on can't be shared, but I am taking photos for after Secret Santa is over.

Garage electrical for outlets finished as well as getting insulation up. My dad came over for a bit yesterday, and we managed to finish the prep for drywall and get up the first 3 panels. Should be able to get that finished this week and then I've got a guy coming over to do the garage doors wall, ceiling, taping, and mudding.



Rakshasa build made good progress with all core armor parts printed along with the Firefall helmet. Starting on the shoulders I'm going with and starting the sanding and filling process.




Finally for what I can share right now, I got back around to making final adjustments for helmet stands. I still need to make a tutorial for these and get the files up for others to use, but basically I wanted it to be something that needed minimal tools outside of some printed parts.



These started working back from the helmet stands Benton made for use at booths and making them something that's simple to make in batches as needed.

Other things in the works include 6 props that all completed printing this month and 3 of them are assembled.

The focus from now until TORG turns to 2 priorities: the garage and my rakshasa build with my Secret Santa items falling immediately after.

 

[EchoCosplay]

Late to the party on this but wow did the photo backdrop wall turn out awesome! The lighting looks so cool with the hexagon panels!

The helmet stand also looks great (I love the built-in slot for a placard!).

 

[mrc0369]

So many awesome projects everyone is working on. I just wish I had more time/printers/money/skills to do everything I want to. Unfortunately I’m only good for one major project per year.

 

[Fallen]

More progress.

Last of the drywall went up on the walls and garage doors got insulation added. Guy doing the ceiling came over last week and started adding some cross braces between the trusses for hanging drywall on the ceiling. He's supposed to be back over tomorrow to finish that part.



For TORG builds I've got some good progress, and am currently in the middle of painting my main colors. Here's some of the previous steps at least. For props making a commando and sidekick.



Got a vacuum form setup as well now and pulled my first visor. 3rd try was the charm as the first pull was too early, second was less too early, and 3rd was near perfect for my needs.


Visor in the helmet shot was actually the 2nd pull. It could have worked, but I wanted better.

Lastly a new friend is going to be joining the fray. Making a mannequin. This guy gets worked on every once in awhile when I'm waiting for something to dry or cure.



That does it for the Sep build updates. Oct ones will come after TORG.

 

[EchoCosplay]

Is the mannequin to display your armour on? Or are you actively going to use it as a base to form/build over?

 

[Fallen]

Display my armor on it. Probably just those that are mostly if not all printed because my cat likes to chew on foam.

 

[EchoCosplay]

I feel you! I have a cat who eats foam (and then throws it back up again, of course). All of my foam projects have to be completely inaccessible to him, so I can never display them out in the open!

 

[FANGS]

I LOVE this. What a great way to keep yourself accountable to, well, yourself! And you get to share some pretty cool projects with all of us!

 

[Fallen]

Not much of an update this month in terms of photos. I need to suit up again and get photos of how the rakshasa turned out.

Rakshasa completed enough in time for TORG. Though I didn't find enough time to suit up for long, I did get to pull it out for a short while on Friday and Sunday. Thanks for Emp Frosty for helping me get at least 1 photo with armor on.



I also finished two props to be able to take with me, a sidekick and a commando.

Mannequin just needs the wrists and hands put on for the upper body to be completed. Everything for the upper body is printed, and the hands have been assembled; I just need to finish assembly on them. I'll be starting printing the lower body this week.



As far as the garage, it is going SLOW. I hired out doing the ceiling as well as the mudding and taping. The guy doing it has limitations in how much time he can spend working on it due to taking care of his granddaughter. As mentioned in my last update he and my dad are adding boards between the trusses for more spots to screw in the drywall. That's the part that's taking awhile as they've had to move electrical boxes, get some of the stuff the previous owners had stored in the "attic" space and other headaches. He's also only able to come over to work a few hours one day a week which makes for slow going. Thankfully this part is almost done, and he expects they can get all of the actual drywall up in a couple of hours one day. Here's hoping. What is has done is give me time to create some mockups of my plans afterwards, and y'all some plans have changed.



November Projects:
- Finish upper body of mannequin
- Start printing lower body
- Reach grenade launcher prop - paint ready