Tag Archives: costume

(Vandal #2b) Neck Revisions/Foam Prep

A short log post this time just to cover a few alterations and updates I’ve made after my bit of hiatus from this project (a lot going on in my life lately…)

First things first, I reinforced a lot of areas with simple cable ties, and in one area, a plastic screwpost, because I noticed the hot glue doesn’t always hold too well to the plastic pieces. The clear rivet-looking things are the screw posts. I also added some HI styrene sheets to certain mild stress areas (around the harness where it moves slightly upon getting in and out of the suit) and both glued and cable tied them to the EVA foam. This way the glued EVA seams won’t come apart, ever. This will all be lined in the future so it won’t look as ugly!

Cable ties are something a lot of people just think of as temporary solutions, but for things like this they work very well. I will mention however, that I do not recommend them for areas that move excessively and hold weight/stretch regularly. They’re very difficult to break or stretch in general, but the more tension or weight you put on them, the easier they’ll eventually snap or stretch. The areas I’ve placed them here are infrequent (or none at all) stress areas, but with the plastic sheeting and the fact that they’re not actually supposed to stretch or move, rather to ensure the areas DON’T move, the usage will be fine. I’ve very rarely had a cable tie snap, and I use them frequently for both permanent and temporary solutions.

Near the end of the neck, I also added a piece of EVA layered with PVC board for a bit of added horizontal crush reinforcement.

I also installed a removable fan (removable via Velcro) that, because its attached to the bars along the sides of the interior helmet, moves with me as I move my head around. The battery box will be hidden inside the mohawk later on. The fan itself is far up enough to where it does not effect my vision through the mouth, and it’s very quiet.

One of the major things I altered in preparation for foaming is alteration of the area just behind where the head pivots. I removed the last ring of the neck and replaced it with a triangular piece that is curved slightly inward. This curvature allows for the head to still move smoothly and slightly overlap when turned left or right. The main reason I did this was because I started noticing how that last ring was actually being impacted by the sides of the head when it would turn, and I knew this would affect the foaming process and likely look weird when complete.

Also in prep for foaming, and now that there was a huge gap in the throat from removing that last ring and only replacing the top with the triangle, I added a single piece of EVA foam in the throat area that is curved up. This will be to attach the foam to and ensure everything stays flexible around that area, since it will need to overlap smoothly. I may or may not also add some mesh here, depending on how the visibility situation goes.

The final thing I did (besides add the start of the mohawk, which I’ll include in the foaming process) is revise the head shape some by cutting some excess foam and sanding it smooth or thinning it out in certain areas, such as behind his eyes where I thought it stuck out far too much upon revisiting this project. I also shaved down the eyebrow area, end of the muzzle, and part of the mouth to make it more straight instead of curved as much into a smile (it still looks like he’s smiling though :D)

As a side note, yes I sometimes work in my Star Wars pajamas 😛

Next journal entry will be on adding the foam, which I’ve already started on at the time of writing this. Remember to join my Discord server or follow me on Ko-fi for exclusive WIP photos even before I release the next log entry!