Movie Quality Jorge Armor

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Da boot
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Whoa, how big is that boot? Do you have a picture that we can see it in scale to something?

Its big enough to add about 2 inchs to my height and will fit a size 13 bluntstone boot. I've planned and designed the Suit out to give me roughly an extra 4 inchs height so I'll be 6'7
 
Small update: Looking at a two way amber mirror so I can vacuform the visor from a sculpt which I will be starting tomorrow, I just washed the dust off of the forearm form and will be priming it tonight, then add the big metal strapping and rivets tomorrow and tada, ready for molding. Boots are coming along nicely, working on the soles tonight, and I decided to pep the thigh pads as I HATE fabricating them from scratch. Posting a few updated pictures tomorrow evening hopefully.
 
Wow!! Amazing build out of foam! I would like to see rivets used as those x's. How did you make it so smooth?! *drool*
 
Smooth? Easy, on top of the foam 2-3 coats of resin, then bondo, then sand and shape and smooth with files, rasps, and 60-80 grit sandpaper, once its uniform do a coat or two of spot filler/glazing putty and sand that smooth with 200 grit wet-dry sand paper, I prefer to sand wet at this stage then prime, wet sand any spots and then do a 2-3 coats of paint for the mold as it fills in most little gaps after that and ta da, ready to be molded. It's gonna be cast in Smooth on black two part plastic with aluminum powder brushed into the mold so if it scratches or rubs any paint off it still looks metal underneath instead of white. I also decided to opt for Metal tapping screws instead of rivets thinking, if I need to do field repairs a screw is a lot easier than a rivet. Blam.
 
You could cut the Thigh out of Foam mats like what I did. The Pep looks great. And the forearm is just fantastic. I was just going to do my UA plate as an attachable. I can't wait to see more!
 
You could cut the Thigh out of Foam mats like what I did. The Pep looks great. And the forearm is just fantastic. I was just going to do my UA plate as an attachable. I can't wait to see more!

Nice Idea but I cant do the Foam mat approach, once the thighs are made in fiberglass and I weather them (scratches and dents) I'm making a silicone mold so I can cast them in a high density rubber so I can move freely but still look as though they are solid. Its done a lot for Stunt armor in film and tv. And I only plan on Making Jorge's armor unless commissioned so I didn't want to waste my time making two pieces.
 
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