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Thread started 27 Feb 2013 (Wednesday) 05:34
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Bazza's Iron-Man suit build

 
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Dec 15, 2015 03:42 |  #631

Both plates for the back of the hands have been bashed into shape and are ready for a couple of detail grooves in the right places. I'll just file them in as they don't need to be too deep.

Now that they both wrap around the sides of the hand, the palm plate with all the raised details doesn't have to be so deep and curved. My shaped-to-match block of insulation foam needs minimal dishing on the inside to conform to the contours of my hand underneath.

Once that's done I can carefully cut in all the details on the outside. With help from Almighty God, I should then be able to cast it as one chunk with the molten aluminium reaching the edges this time as it doesn't have to travel as far.

IMAGE: http://i.imgur.com/vGofsHE.jpg

Builds By Baz website http://www.buildsbybaz​.com (external link)

  
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Dec 15, 2015 03:43 |  #632

Nearly there... Crikey I hope this works....

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Dec 15, 2015 03:43 |  #633

Praise THE LORD!!!!! IT WOOORRRRRRKED!!!!!!!

IT WOOOOOORRRRRKKKKKKEEEE​EDDDDDD!!!!!!

1. Lots of sprues glued on to let the molten metal in.

IMAGE: http://i.imgur.com/0lpyWPX.jpg

2. Buried in the sands of hope and dreams.

IMAGE: http://i.imgur.com/JPpPPaQ.jpg

3. I deserve to hit the hay early tonight!

IMAGE: http://i.imgur.com/atuL9c8.jpg

4. But first, a nightcap in celebration of my pure awesomeness.

IMAGE: http://i.imgur.com/VIbaTLC.jpg

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Dec 15, 2015 03:43 |  #634

The clean-up begins....

IMAGE: http://i.imgur.com/9pWhwIe.jpg

IMAGE: http://i.imgur.com/153L2DY.jpg

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Dec 15, 2015 03:44 |  #635

Work continues. Diamonds in the rough.

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Dec 15, 2015 03:44 |  #636

Slowly coming together. All the grinding, filing and sanding is VERY fiddly and time-consuming.

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Dec 15, 2015 03:45 |  #637

Today I took both cast pieces to my contact who wishes to remain unknown for him to help me out with a quick clean-up on the lathe of the centre circles in the palms.

From here on in, all the finishing and clean-up is by hand with sandpaper and files.

IMAGE: http://i.imgur.com/vVi8HS7.jpg

IMAGE: http://i.imgur.com/iXYlicH.jpg

IMAGE: http://i.imgur.com/NdhX0R0.jpg

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Dec 15, 2015 03:45 |  #638

I don't get access to this kind of machinery often, but today I asked a favour and was granted it. Nicely timed.

People have been asking me what tools I use to shape my metal. Although I occasionally get access to some advanced machinery, most of the work is done with primitive hand tools and good old elbow grease.

IMAGE: http://i.imgur.com/sao6NUE.jpg

IMAGE: http://i.imgur.com/NQCmLFQ.jpg

IMAGE: http://i.imgur.com/VkncEGo.jpg

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Dec 15, 2015 03:46 |  #639

Marking out all the friction points to grind back and refine fit and improve range of motion.

IMAGE: http://i.imgur.com/Y6kWRbs.jpg

All finger armour pieces for the other hand now cast. Looks like I have many hours of grinding ahead of me.

IMAGE: http://i.imgur.com/Y1vjhzv.jpg

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Dec 15, 2015 03:46 |  #640

IMAGE: http://i.imgur.com/Hkft1Ef.jpg

IMAGE: http://i.imgur.com/c0G1bdg.jpg

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Dec 15, 2015 03:46 |  #641

Bought a pretty important bit of kit for what's coming up next with the suit - installing electronics and lighting.

Getting exciting!

IMAGE: http://i.imgur.com/gqTBgUA.jpg

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Dec 15, 2015 03:47 |  #642

**** slap anyone? :lol:

Hand back-plates detailed, sanded and polished.

IMAGE: http://i.imgur.com/kiAQEvJ.jpg

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Post edited over 6 years ago by Pekka with reason 'fixed video tags'.
     
Dec 15, 2015 03:47 |  #643

Here's a quick video from this morning's cast.




Here's how it pulls from the sand.



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Dec 15, 2015 03:47 |  #644

I got a bit bored doing armour every night so I thought I'd gave fun carving and casting instead.

IMAGE: http://i.imgur.com/jRfGDwd.jpg

IMAGE: http://i.imgur.com/YoqK27O.jpg

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Dec 15, 2015 03:48 |  #645

I'm always a big believer of running concurrent projects - and as I managed to drop and badly damage a lot of parts of my previous arc reactor, hopefully this is the last arc reactor I'll ever have to make.

Thanks to a close friend who wishes to remain anonymous, the two of us are collaborating very closely to machine and assemble the ultimate power plant. He is machining the major components, while I am researcher, consultant and assembler of small detail.

IMAGE: http://i.imgur.com/Z4UZxlj.jpg

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Bazza's Iron-Man suit build
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