Another update of sorts.
I thought I'd outline the entire process of making an ODST Flashbang grenade (
http://halo.wikia.com/wiki/Flashbang_grenade) out of foam. It is a very simple design and shape, and if you're new to working with foam, then this could be a really great practice for you before tackling the more complicated pieces of armor and equipment.
First, here's what you'll need:
Xacto Knife
Scissors
Template of what I'm calling the TMNFB Mask. (
see below for link)
A rectangular piece of standard EVA foam that's 6 x 4.5 inches.
A sheet of 6mm craft foam
A sheet of 2mm craft foam
A heat gun
Belt Sander (or a really shard knife and an amazing ability to cut angled curves)
Hot Glue Gun (w/glue sticks..duh)
Gaffer's Tape (or if unavailable, painter's blue tape will work)
Metal Straight Edge (ruler)
Plasti Dip Spray
Spray Adhesive
Olive Drab Paint
Silver Paint
Yellow Paint
Black Tempra Paint mixed with water in a spray bottle (Blackwash)
I use EVA foam for the main body (tube) because it has a good solid feel once it's completed and the thin stuff (
6mm craft foam) is a little too flimsy. Heat up the EVA foam on both sides, moving the heat gun about six inches above the surface to prevent burning the foam. Keep the heat gun moving and don't sit in one place too long. You can tell when the foam is heated up because it will turn a slightly darker shade of gray. Flip the piece over and repeat until both sides are heated up. Then bend/curl the foam, textured side in, into a tube, using the gaffer's tape to hold it together. Be sure to match up your edges or the tube will be cock-eyed and wonky, and no one wants that. You want it to look like the photo below.
Next, squeeze/pour/apply hot glue into the tube over the seam. This will help weld the tube together and hold it's shape. Once that's dried/cured, take the tube and stand it onto the sheet of 6mm Craft foam and trace around it.
Next, take a pair of scissors and cut out around these circles, leaving about a cm around the line. This will act as an overhang when you glue the pieces onto the tube.
Apply a standard bead of hot glue on one end of the tube, keeping it towards the center hole of the tube. This helps cut down on glue seepage when putting the pieces together. Place the 6mm foam circle onto the tube, then flip it over so that the 6mm piece is on the table. Now press down on the tube. This will help keep the 6mm foam straight and flat during the gluing process.
Repeat this step for the other end of the tube and allow to cure/dry and then remove the tape.
Print out the supplied template at 100% scale. The template is 180mm long and 40mm tall. Here is the link for the full size template:
http://i169.photobucket.com/albums/...y/ODSTGrenadeMaskTemplatecopy_zpsc723cfbb.jpg
Now it's time to make the TMNFB masks for your grenades. Trace out the template on the sheet of 2mm Craft Foam and cut it out, leaving on a few centimeters on on side of it.
Place the cut out 'mask' on a sheet of wax paper and spray an even coat of spray adhesive on one side of it. The wax paper is to keep the adhesive from getting all over the work surface. Note in the picture below how there is extra foam extending past the right side. This is to ensure both sides meet in the back when you wrap it around the tube.
Now carefully wrap the mask around the tube, centering the mask opening to the front of the tube, keeping the tube's seam in the back. Be sure to push the top edge of the mask up to the overhanging circle of 6mm foam at the top of the tube. Once both sides have met in the back, use a knife to trim away the excess so that the edges are flush. Put a small bead of hot glue on the back seam to reinforce it. You now have a proud member of the Teenage Mutant Ninja Flashbangs! (
Now you know what TMNFB means. Hyuck.)
Next comes the belt sander. I have a small, Task Force brand unit that cost me under $100 at Lowes. If you can get one of these, I would highly suggest it, especially for foam work as it allows you to shape the foam very, very easily. First, using the belt sander, carefully sand off the excess 6mm foam from the top and bottom of the tube, like shown below.
Next, hold the tube at around a 45 degree angle and sand around the entire circumference of the top and bottom, as shown below.
Now your Flashbang is constructed! Next comes the paint.
First you need to seal your foam with the Plasti Dip spray. There are other methods of sealing foam, but honestly, this is the easiest and the best, so just do it. I usually put around three to four coats of Plasti Dip on my pieces to ensure they are completely sealed. The grenade on the right has been sprayed with the first coat of Plasti Dip.
Once the Plasti Dip has dried/cured fully (about 30 min per coat) spray the entire grenade olive drab, as shown below.
Next you'll want to mask off an rectangle on the front to spray your indicator color. Flashbangs are coded Yellow, so that's what I did. When the ywllow is still wet, I usually scratch it up with a nail, pen lid, or whatever else is lying around the shop to give it a weathered look. Once the yellow dries, mask of the entire tube except the bottom and the 'mask' and top. These will be painted silver.
Once the paint has completely dried, use some high grit sandpaper to rough up the silver a little. This helps the blackwash stick to it. (Below, you can see the blackwash beading up on the silver because I forgot to do this step.) Once that's done, spray the whole grenade with the black wash as shown below.
Let the blackwash sit for a few minutes then wipe down with a dry rag. Spray it again. Wipe it down again. Then, spray it one more time, but this time set the grenade on it's top to let the blackwash seep into and cake-up the bottom edge of the 'mask'. Then blot at it with the rag, leaving a nice texture across the entire surface and viola! You have this:
You now have a UNSC Issue Flash Bang Grenade to hang on your hip plate, or wherever you feel like hanging it.
Wondering what those things are that the grenades are sitting on during the painting process? My next post will discuss them and show pictures of them so you can make your own!
Comments and questions are appreciated!