Update time...
It's been a few days since I've posted anything of interest. So here goes. I've started working on the underside of the brim. I will explain step by step what I have done as I go.
I've taped off the brim to contain the overall shape of the layer that I will be adding. When complete it will be about 2.5mm high and be recessed by about 2mm from the outer edge of the brim.
Applied the first of two coats of filler, this first coat will act as a 'foundation' for the overall detail. Once the filler cures up to a rubbery solid I will **gently** pull back the tape piece by piece while pressing down on the adjacent side to prevent lift off.
Once the tape is removed, I clean up the outer edge of the layer with a razor blade; reinforcing it's shape.
After the second filler coat is applied and has cured fully the measuring starts. As shown in the image above, I clean the outer edge of the shape. I do this for 2 reasons;
1. It is far less sanding later, preventing any possible damage to the underlying brim.
2. It gives me a smooth reference point that allows me to completely level this new layer.
What I do it draw a line to indicate the final overall height of this layer. This line goes around the whole piece at about 2.5mm off the face of the brim. Once the line is committed, using a smoothing file; I file the perimeter of the layer on a 45 degree angle bringing the height down to the pencil line I made earlier that outlines the layer. This makes the outer edge uniform and level around the whole layer.
Next, I shade in another line around the face of the layer (as seen below). I use a rasp (flat and level) on the layer and from left to right begin removing material slowly and evenly. Because the outer edge of the layer is on a 45 degree angle, when I file against the face of the layer it will not remove any further material from the outer edge until the piece as a whole is filed down to that level. When the shaded line begins to fade, I stop as that area is now level with the outer edge, and I move on to the right.
Once the rough filing is done, I'm left with a nice level surface.
After a sanding with 120grit, I glaze the whole area with spot putty to fill in all tooling marks and sanding lines.
Once the glaze is cured, it gets another sanding with 120.
Lather, rinse, repeat...
Once again setting up, now to do the final under brim details. I thought about doing this after the face with foam or plastic pieces, but I figured... what the hell. I'm here now, why not go a bit further.
Lather, rinse, repeat... yet again!
As I wait for the glazing layer to dry, I figured that I would take some profile pictures to show the overall look of the additions to the brim. The lower of the two layers that I added blends perfectly with the existing chamfer from the side of the brim. Everything is smooth and equal.
This is as far as I will take it today, not because I'm tired, but because this glaze must cure completely or it will have a crumbly consistency and I will just have to do it over again. I'll pick up from here later today with a final sanding and the top layer will get cut up into its final shapes.
Well that's it for now, another update will come later on today... :cool
Till then;
BLARG, BLARG!!
Cereal.
