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	<title>Punished Props</title>
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	<link>http://props.punishedpixels.com</link>
	<description>The very best in custom replica props by crafting wizard Bill Doran.</description>
	<lastBuildDate>Wed, 22 May 2013 17:13:08 +0000</lastBuildDate>
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		<title>Portal 2 &#8211; Long Fall Boots</title>
		<link>http://props.punishedpixels.com/2013/04/30/portal-2-long-fall-boots/</link>
		<comments>http://props.punishedpixels.com/2013/04/30/portal-2-long-fall-boots/#comments</comments>
		<pubDate>Tue, 30 Apr 2013 17:21:45 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Costume]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=2438</guid>
		<description><![CDATA[I got a commission to build a pair of the Long Fall boots from Portal 2. I figured this would be a pretty extreme test of my ability to create something that actually served a function. I had a little help with the design; my wife created similar boots a couple of years ago for [...]]]></description>
				<content:encoded><![CDATA[<p>I got a commission to build a pair of the <a title="http://youtu.be/wX9Sc88qreg" href="http://youtu.be/wX9Sc88qreg">Long Fall boots</a> from Portal 2. I figured this would be a pretty extreme test of my ability to create something that actually served a function. I had a little help with the design; my wife created similar boots a couple of years ago for her <a title="http://www.flickr.com/photos/doranwa/sets/72157627510838729/" href="http://www.flickr.com/photos/doranwa/sets/72157627510838729/">Chell costume</a>. The main difference in my design was that they would be made from EVA foam.</p>
<p><img class="alignnone size-full wp-image-2441" alt="Chell Boots Finished" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-10-6-01-08-PM.jpg" width="575" height="767" /></p>
<p>There have been several ways that people have solved the problem of the heels on these boots. I decided to go the same route as my wife and build them on existing high heeled shoes with clear plastic heels. I nabbed these 4&#8243; stripper heels from Amazon in the appropriate size for the client.</p>
<p><img class="alignnone size-full wp-image-2442" alt="Long Fall Boots - Stripper Heels" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Mar-27-1-34-41-PM.jpg" width="575" height="767" /></p>
<p>The outer shell of the boots were created from heat formed EVA foam floor mats. For the most part, these were templated on the fly in a very &#8220;trial and error&#8221; method. What you see in the final product is not the first try, not by a long shot. After taking measurements from the stripper heels, I laid out a flat paper template and cut it out of the foam then formed it by hand with a heat gun.</p>
<p>The real trick was figuring out a way to build the covering in pieces, then design a way to cover all of the seams. When I had the toe pieces formed, I attached them to the shoes with contact cement.</p>
<p><img class="alignnone size-full wp-image-2443" alt="Long Fall Boots - Toe Parts" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-01-2-51-12-PM.jpg" width="575" height="431" /></p>
<p>The back parts of the boots were done in the same manner, but made from two pieces so that I could form a complex curve along the back side of the leg. Again, these pieces were heat formed by hand until the fit nice and snugly around the shoe. I designed the connecting elements of the template to be a little big so that I could trim them to size once I had the forms figured out.</p>
<p><img class="alignnone size-full wp-image-2444" alt="Long Fall Boots - Backs" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-01-4-21-53-PM.jpg" width="575" height="431" /></p>
<p>The back pieces were also attached to the stripper heels with contact cement. The plastic ankle strap inside of the shoe was eventually removed entirely after a test fitting on a friend with appropriately sized feet (my size 12 boats wouldn&#8217;t even come close to fitting into these things).</p>
<p><img class="alignnone size-full wp-image-2446" alt="Long Fall Boots - Backs Attached" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-03-11-36-48-AM.jpg" width="575" height="431" /></p>
<p><img class="alignnone size-full wp-image-2447" alt="Long Fall Boots - Inside Heels" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-03-11-36-57-AM.jpg" width="575" height="431" /></p>
<p>These jerks were no help at all.</p>
<p><img class="alignnone size-full wp-image-2448" alt="Long Fall Boots - Turrets" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-08-10-42-03-AM.jpg" width="575" height="431" /></p>
<p>I sanded down the seam between the front and back pieces with a drum sanding bit in my drill press. The plan was to cover this seam with white EVA foam later on.</p>
<p><img class="alignnone size-full wp-image-2449" alt="Long Fall Boots - Seam Sanded" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-03-11-56-04-AM.jpg" width="575" height="431" /></p>
<p>With the shape all figured out, I covered the gray foam with a 2mm thin EVA craft foam. This was done with contact cement and took several tries. This kind of covering is prone to wrinkles. Lots of swearing happened.</p>
<p>Also, not pictured is the flat piece at the top/back of the boot where the spring piece would be attached. It&#8217;s a rectangular piece of 1/4&#8243; PVC with three holes drilled into it. It was cemented to the back of the boot before the white covering was applied.</p>
<p><img class="alignnone size-full wp-image-2450" alt="Long Fall Boots - Foam Cape" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-08-1-39-18-PM.jpg" width="575" height="767" /></p>
<p><img class="alignnone size-full wp-image-2451" alt="Long Fall Boots - Foam Cape 2 - The Wrinkling" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-08-1-39-27-PM.jpg" width="575" height="767" /></p>
<p>Again, I can&#8217;t reiterate enough how much of this build was a frustrating trial and error process. Here you can see some of the wrinkles. I ended up ripping off and sanding most of the white foam off for a 2nd try.</p>
<p><img class="alignnone size-full wp-image-2452" alt="Long Fall Boots - Damned Wrinkles" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-08-4-10-50-PM.jpg" width="575" height="767" /></p>
<p>Eventually I was able to get a satisfactory covering on the boots. The black heel parts were done in 2mm black EVA craft foam and the white parts were overlapped over them.</p>
<p><img class="alignnone size-full wp-image-2454" alt="Long Fall Boots - Victory" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-09-2-46-48-PM.jpg" width="575" height="767" /></p>
<p>The toe coverings were done the same way, just with a couple of layers of the white to get the seams the way they needed to look in the reference. I generally tried to template the pieces too big, cement them down, then trim the extra that flopped over the sides.</p>
<p><img class="alignnone size-full wp-image-2455" alt="Long Fall Boots - Toe Foam" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-09-4-10-10-PM.jpg" width="575" height="431" /></p>
<p><img class="alignnone size-full wp-image-2456" alt="Long Fall Boots - Toe Foam Strikes Back" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-09-5-38-28-PM.jpg" width="575" height="431" /></p>
<p>The toe tip was painted black with some enamel paint and the lines were drawn in with a fine tipped marker then painted over with enamels.</p>
<p><img class="alignnone size-full wp-image-2457" alt="Long Fall Boots - Black Toes" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-10-1-10-12-PM.jpg" width="575" height="767" /></p>
<p>The heel springs were actually quite straight forward. Since the client would be standing on her shoe heels, the springs didn&#8217;t need to do anything other than look good. I built them from thin strips of aluminum. It was easy enough to bend to shape by hand. I reinforced the bottom part with another layer of aluminum and some J.B. Weld.</p>
<p><img class="alignnone size-full wp-image-2458" alt="Long Fall Boots - Springs" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-10-12-46-52-PM.jpg" width="575" height="431" /></p>
<p>The stripper heels came with a plastic cap over an attachment rivet thing. I was able to pry the plastic cap off and repurpose the rivet through a hold drilled in the heel springs.</p>
<p><img class="alignnone size-full wp-image-2459" alt="Long Fall Boots - Heel Rivet" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-10-1-05-35-PM.jpg" width="575" height="431" /></p>
<p>The tops of the springs got three holes drilled into them to match the attachment points on the back of the boots. After a quick black spray paint on the springs, they got glued into the boots with some hex bolts.</p>
<p><img class="alignnone size-full wp-image-2460" alt="Long Fall Boots - Hex Bolts" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-10-5-09-15-PM.jpg" width="575" height="767" /></p>
<p>The very last thing the boots needed was a way to keep them attached to the client&#8217;s legs. I added a couple of nylon webbing/velcro straps to each boot along with a D-ring so that they could be tightened to size.</p>
<p><img class="alignnone size-full wp-image-2461" alt="Long Fall Boots - Strapped" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-10-5-19-24-PM.jpg" width="575" height="767" /></p>
<p>Done and done!</p>
]]></content:encoded>
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		</item>
		<item>
		<title>Darker than Black &#8211; Hei&#8217;s Daggers</title>
		<link>http://props.punishedpixels.com/2013/04/02/darker-than-black-heis-daggers/</link>
		<comments>http://props.punishedpixels.com/2013/04/02/darker-than-black-heis-daggers/#comments</comments>
		<pubDate>Tue, 02 Apr 2013 21:42:44 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Prop]]></category>
		<category><![CDATA[featured]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=1844</guid>
		<description><![CDATA[A couple of months ago I got my hands on a commission to build Hei&#8217;s Daggers from the anime show Darker than Black. Fortunately for me, my pal Harrison from Volpin Props had already made the dagger and has blueprints available for an insanely low price of $5. Having the blueprints already done usually saves me [...]]]></description>
				<content:encoded><![CDATA[<p>A couple of months ago I got my hands on a commission to build Hei&#8217;s Daggers from the anime show <a title="http://en.wikipedia.org/wiki/Darker_than_black" href="http://en.wikipedia.org/wiki/Darker_than_black">Darker than Black</a>. Fortunately for me, my pal Harrison from <a title="http://volpinprops.blogspot.com/2009/06/heis-daggers-darker-than-black.html" href="http://volpinprops.blogspot.com/2009/06/heis-daggers-darker-than-black.html">Volpin Props</a> had already made the dagger and has <a title="http://www.volpinprops.com/shop/heis-dagger-darker-than-black-digital-file/" href="http://www.volpinprops.com/shop/heis-dagger-darker-than-black-digital-file/">blueprints available</a> for an insanely low price of $5. Having the blueprints already done usually saves me 1-2 days of research and drawing. I have my own blueprints available <a title="http://props.punishedpixels.com/product-category/blueprints/" href="http://props.punishedpixels.com/product-category/blueprints/">for sale here</a>!</p>
<p><img class="alignnone size-full wp-image-1848" alt="Hei's Daggers - Finished" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/DSC_4780.jpg" width="575" height="291" /></p>
<p>I printed up the designs full scale and got started! My plan for this was pretty similar to the way that Harrison built it. I planned out several layers of PVC sheet and styrene in different thicknesses.</p>
<p><img class="alignnone size-full wp-image-1849" alt="Hei's Daggers - Design" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Feb-07-10-50-01-AM.jpg" width="575" height="767" /></p>
<p>Most of the pieces were cut out with an X-Acto knife. Some of the thicker parts were cut out with my scroll saw. The layers were all epoxied together.</p>
<p><img class="alignnone size-full wp-image-1850" alt="Hei's Daggers - Layers" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Feb-07-2-30-13-PM.jpg" width="575" height="431" /></p>
<p><img class="alignnone size-full wp-image-1851" alt="Hei's Daggers - More Layers" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Feb-07-3-21-55-PM.jpg" width="575" height="767" /></p>
<p>The beveled edges on the side of the dagger were filled in with Bondo. I also added more styrene to the blade tips to reinforce them.</p>
<p><img class="alignnone size-full wp-image-1852" alt="Hei's Daggers - Bondo" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Feb-07-6-34-54-PM.jpg" width="575" height="431" /></p>
<p><img class="alignnone size-full wp-image-1853" alt="Hei's Daggers - Filled" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Feb-07-6-34-58-PM.jpg" width="575" height="767" /></p>
<p>Once it was all filled in and sanded down, I got it all primed up and did some more sanding.</p>
<p><img class="alignnone size-full wp-image-1855" alt="Hei's Daggers - Primed" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Feb-07-9-54-15-PM.jpg" width="575" height="767" /></p>
<p>At this point, it was all ready for molding! Originally I thought I would need to cast it with some steel wire inside of the plastic for strength. This actually made the blades bow quite a bit, so I tried casting one without the wire. The non wire blade casting was incredibly durable and didn&#8217;t bow at all!</p>
<p><img class="alignnone size-full wp-image-1856" alt="Hei's Daggers - Casting Wire" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Mar-18-12-41-47-PM.jpg" width="575" height="767" /></p>
<p>The finished blades were cast from SmoothCast 300 with a little bit of SoStrong black tint.</p>
<p><img class="alignnone size-full wp-image-1858" alt="Hei's Daggers - Cast Blades" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Mar-18-6-34-28-PM.jpg" width="575" height="767" /></p>
<p>With the pieces all cast, they needed just a little bit of sanding and some paint! The base color was a rattle can metallic paint. Then I masked off the edges of the blade to paint the rest of it black.</p>
<p><img class="alignnone size-full wp-image-1859" alt="Hei's Daggers - Silver Paint" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Mar-27-8-48-19-AM.jpg" width="575" height="431" /></p>
<p><img class="alignnone size-full wp-image-1860" alt="Hei's Daggers - Painted" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Mar-28-8-29-36-PM.jpg" width="575" height="767" /></p>
<p>After some clear coating, I did some light touch up weathering with a dry brushed black paint and some silver leaf Rub &#8216;N Buff.</p>
<p><img class="alignnone size-full wp-image-1861" alt="Hei's Daggers - Weathering" src="http://props.punishedpixels.com/wp-content/uploads/2013/04/Photo-Apr-01-11-07-40-AM.jpg" width="575" height="431" /></p>
<p>That&#8217;s it! All done! Nothing to see down here!</p>
]]></content:encoded>
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		<slash:comments>4</slash:comments>
		</item>
		<item>
		<title>Starcraft 2 &#8211; Kerrigan&#8217;s Ghost Rifle</title>
		<link>http://props.punishedpixels.com/2013/03/14/starcraft-2-kerrigans-ghost-rifle/</link>
		<comments>http://props.punishedpixels.com/2013/03/14/starcraft-2-kerrigans-ghost-rifle/#comments</comments>
		<pubDate>Thu, 14 Mar 2013 19:05:46 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Prop]]></category>
		<category><![CDATA[featured]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=1695</guid>
		<description><![CDATA[A couple of months ago, the video card on my 5 year old PC finally gave up the ghost. I reached out on twitter to see if anyone had a spare around that could keep me going for a while longer. The folks at Doghouse Systems contacted me and we ended up formulating a plan [...]]]></description>
				<content:encoded><![CDATA[<p>A couple of months ago, the video card on my 5 year old PC finally gave up the ghost. I reached out on twitter to see if anyone had a spare around that could keep me going for a while longer. The folks at <a title="http://www.doghousesystems.com/" href="http://www.doghousesystems.com/">Doghouse Systems</a> contacted me and we ended up formulating a plan that involved them sending me a whole new computer in exchange for me building them Kerrigan&#8217;s Ghost rifle to use as a promotional giveaway. What a fantastic plan! I was so excited for the project and I jumped right on it!</p>
<p><img class="alignnone  wp-image-1706" alt="Ghost Rifle - Finished" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/DSC_4407-1024x575.jpg" width="553" height="311" /></p>
<p>I knew that I would need to make more than one copy of this gun, so I planned on building it in a series of parts that would be molded. Since I was on a tight deadline, photo coverage was a bit spotty, so I&#8217;ll do my best to paint you some pretty word pictures.</p>
<p>Of course I drew up some really detailed blueprints. Like always, I printed it out full scale to use as templates. In fact, the blueprints are for sale <a title="http://props.punishedpixels.com/shop/kerrigan-rifle-blueprint/" href="http://props.punishedpixels.com/shop/kerrigan-rifle-blueprint/">on my store here</a>!</p>
<p><img class="alignnone  wp-image-1709" alt="Ghost Rifle - Blueprints" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-12-1-35-08-PM-768x1024.jpg" width="553" height="737" /></p>
<p>I started with one of the most complicated pieces; the scope. I cut out the side and top profile shapes out of 1/4&#8243; MDF and glued them together. The empty space between them was filled in with rigid insulation foam. This cheap, lightweight material is great for taking up space inside the body of a prop piece.</p>
<p><img class="alignnone  wp-image-1707" alt="Ghost Rifle - Scope Foam" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/scpope_foam-1024x567.jpg" width="553" height="306" /></p>
<p>Then I covered most of it in Apoxie Sculpt. This stuff is amazing. I sculpted it down to a close approximation of the scope shape and was able to sand and refine it after it cured.</p>
<p><img class="alignnone  wp-image-1711" alt="Ghost Rifle - Scope Sculpt" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Jan-31-7-24-07-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The detail pieces on the scope were cut and shaped from PVC foam, styrene, and MDF.</p>
<p><img class="alignnone  wp-image-1710" alt="Ghost Rifle - Scope Heat Sink" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Jan-31-8-12-22-PM-1024x768.jpg" width="553" height="415" /></p>
<p>I lathed the front element of the scope from a chunk of extra polyurethane plastic. The hood cover was cut from thin styrene and glued into place. Everything was sanded and smoothed down into the final shape.</p>
<p><img class="alignnone  wp-image-1712" alt="Ghost Rifle - Scoped" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-02-1-04-28-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The barrel was actually one of the more straight forward parts on this project. Of course I did most of it on my lathe, but it was way longer than my lathe, so I did it in two pieces. The lathe blanks were cast from polyurethane resin in cups and tubes that were roughly the right size and shape as the final parts. I also sunk PVC tubes into them to save on space.</p>
<p><img class="alignnone  wp-image-1713" alt="Ghost Rifle - Lathe Blanks" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Jan-31-7-22-19-PM-768x1024.jpg" width="553" height="737" /></p>
<p>Both barrel pieces got turned on the lathe and everything got primed/sanded a bunch. The plastic resin ended up with a bunch of tiny bubbles that were a pain to fill in, so it took a couple of tries.</p>
<p><img class="alignnone  wp-image-1714" alt="Ghost Rifle - Lathed" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-03-9-02-44-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The two barrel pieces were attached into one large piece. The vent holes required a bit of engineering to get right. I ended up modifying a cheap spade bit to perfectly drill the holes and the recessed bits around the outside of them with my drill press.</p>
<p><img class="alignnone  wp-image-1716" alt="Ghost Rifle - Vent Holes" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-17-2-58-50-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The more oblong vent hole things were a different story. I ended up making templates out of some thin aluminum sheet, taping them down to the surface of the barrel, and cutting them with a router bit on my Dremel.</p>
<p><img class="alignnone  wp-image-1717" alt="Ghost Rifle - Barrel Slots" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-17-3-26-50-PM-1024x768.jpg" width="553" height="415" /></p>
<p>The receiver of the gun was where I spent most of my build time. This part, by itself, is bigger than any other gun project that I&#8217;ve built. It started it&#8217;s life as a couple of sheets of 3/4&#8243; particle board. In hind sight it would have been way better to use MDF, but I didn&#8217;t have any on hand at the time and I needed to get started toot-sweet. The two cut out shapes were glued together.</p>
<p><img class="alignnone  wp-image-1719" alt="Ghost Rifle - Receiver Wood" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-12-2-45-41-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The magazine was made in the same fashion. I started adding slices of detail that were cut out of PCV foam and styrene. It was at this point that I realized that I could get MDF in an 1/8&#8243; thickness and should have been using that instead of the vastly more expensive 1/8&#8243; PVC.</p>
<p><img class="alignnone  wp-image-1720" alt="Ghost Rifle - Receiver Magazine" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-12-9-23-07-PM-1024x768.jpg" width="553" height="415" /></p>
<p>The magazine got some more refinement and beveling. I also added a hex shaped screw. Everything in the future is hexagon shaped, by the way. I also cut out some thicker, sloped pieces out of MDF for the front end of the receiver. If you squint, you can also see where I cut out a hole and added a tube to receive the barrel where it attaches to the main body of the gun.</p>
<p><img class="alignnone  wp-image-1722" alt="Ghost Rifle - Magazine Done" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-13-6-19-05-PM-1024x768.jpg" width="553" height="415" /></p>
<p>The front end of the receiver was quite a challenge. I ended up using a combination of Bondo and Apoxie Sculpt to get the shapes just right. The side stripes were cut from styrene.</p>
<p><img class="alignnone  wp-image-1724" alt="Ghost Rifle - Receiver Front" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-19-9-20-29-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The weird rib things across the grip were also shaped from Apoxie Sculpt, right over the parts that I had shaped earlier.</p>
<p><img class="alignnone  wp-image-1725" alt="Ghost Rifle - Rib Things" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-06-5-44-25-PM-768x1024.jpg" width="553" height="737" /></p>
<p>I also got a head start on the butt stock. The main form was cut from 3/4&#8243; MDF (yes I went and bought some, screw particle board). The tiny piston thingie was lathed from a dowel and I carved in some detail slots with my Dremel.</p>
<p><img class="alignnone  wp-image-1726" alt="Ghost Rifle - Butt Stock Baby" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-24-9-02-37-PM-1024x768.jpg" width="553" height="415" /></p>
<p>All of the detail pieces for the butt stock were cut from 1/4&#8243; MDF, 1/8&#8243; MDF and 1/16&#8243; styrene. This is the &#8220;slicing&#8221; technique that I use for just about all of my gun builds.</p>
<p><img class="alignnone  wp-image-1727" alt="Ghost Rifle - Stock Details" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-04-10-01-30-PM-1024x768.jpg" width="553" height="415" /></p>
<p>To create a matching surface where the stock and receiver meet, I employed a technique known as the &#8220;Bondo Squish&#8221;. I put tape on one side and smeared Bondo on the other and then squished them together, holding them in place. When the Bondo was mostly set, I pulled the pieces apart and let the Bondo cure. The extra Bondo was trimmed away and sanded smooth. This way these two separate pieces would have a tight fit when attached for the final build.</p>
<p><img class="alignnone  wp-image-1729" alt="Ghost Rifle - Bondo Squish" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-06-12-46-21-PM-1024x768.jpg" width="553" height="415" /></p>
<p>The stock was finished, primed and sanded. The large, flat head screws were shaped out of a piece of dowel and cast using a clay push mold. The things that look like Philip&#8217;s head screws are actually Philip&#8217;s head screws. Here you can see that it resembles some kind of space chicken. It is my new shop mascot.</p>
<p><img class="alignnone  wp-image-1730" alt="Ghost Rifle - Space Chicken" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-05-6-44-21-PM-1024x768.jpg" width="553" height="415" /></p>
<p>The receiver also got lots of sanding and priming. I also finished up the detail parts like the trigger, trigger guard, and barrel hood. Most of that was done with layers of MDF and styrene in different thicknesses, just like everything else.</p>
<p><img class="alignnone  wp-image-1732" alt="Ghost Rifle - Master Completed" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-07-3-44-37-PM-1024x768.jpg" width="553" height="415" /></p>
<p>I could have just painted the gun up at this point and called it a day, but I knew that I needed more than one copy of this gun, so I set about making some molds. This was by far the most time consuming, tedious, expensive, and emotional part of the build process.</p>
<p>I started with the barrel. For this one I tried something new. To save on silicone costs and time, I made it a one part mold. I used a wide PVC pipe as my mold jacket, centered the barrel in it, and poured in the liquid silicone from the top. Also, in the master of the barrel, I included a nub inside the barrel that would later be used to hold a threaded rod in the casting.</p>
<p><img class="alignnone  wp-image-1733" alt="Ghost Rifle - Barrel Mold Pour" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-06-9-20-54-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The PVC tube had been split on both sides, prior to pouring the silicone, with hinges on one side so that the mold jacket was kind of a clam shell. When the silicone cured, I cracked it open and cut a wavy seam in the side of the mold that was 90 degrees off from the slit in the mold jacket. I was able to retrieve the barrel master at this point and start casting barrels!</p>
<p><img class="alignnone  wp-image-1735" alt="Ghost Rifle - Barrel Mold" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/barrel_mold-1024x628.jpg" width="553" height="339" /></p>
<p>Again, I added a threaded steel rod into the casting before pouring my resin. This would ensure that the barrel was nice and strong as well as having a great way to attach it to the main gun body. I also added some insulation foam (not pictured) to the rod to take up some space inside the casting.</p>
<p><img class="alignnone  wp-image-1736" alt="Ghost Rifle - Barrel Casting" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-07-10-51-52-AM-768x1024.jpg" width="553" height="737" /></p>
<p><img class="alignnone  wp-image-1737" alt="Ghost Rifle - Barrel Cast" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-07-10-58-32-AM-768x1024.jpg" width="553" height="737" /></p>
<p>The scope mold was not so rousing of a success. My first attempt ended in a catastrophic clay blowout, resulting in a failed mold and a lot of wasted silicone. There were a number of factors that led to this failure. First, the walls of the mold box were way too thin. I used 1/8&#8243; MDF and I needed at least 1/4&#8243;. Second, I didn&#8217;t put in enough clay to keep it stuck to the sloped underside of the scope master. Last, I poured in three batches of uncured silicone into the box all at once, filling the box. This added a lot of liquid weight to the clay. For the second attempt I let the first batch of silicone cure a little bit before adding the remaining goo.</p>
<p><img class="alignnone  wp-image-1738" alt="Ghost Rifle - Failed Mold" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-07-9-42-37-PM-1024x1024.jpg" width="553" height="553" /></p>
<p>The rest of the molds were pretty straight forward. They were all two part box molds. I did a LOT of claying. The receiver piece was especially time consuming. It was easily the largest mold I&#8217;ve ever made.</p>
<p><img class="alignnone  wp-image-1739" alt="Ghost Rifle - Mag Mold" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-08-8-40-42-PM-1024x768.jpg" width="553" height="415" /></p>
<p><img class="alignnone  wp-image-1740" alt="Ghost Rifle - Receiver Clay" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-09-8-58-17-PM-1024x768.jpg" width="553" height="415" /></p>
<p>It took me 4 straight days of work to make the molds. It was a very trying time for me, but I made it through to the other side relatively unscathed! Casting the parts was actually pretty straight forward and extremely satisfying.</p>
<p><img class="alignnone  wp-image-1742" alt="Ghost Rifle - Receiver Cast" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-10-10-48-02-PM-768x1024.jpg" width="553" height="737" /></p>
<p>I painted the entire gun with Model Master&#8217;s buffable metalizer laquer airbrush paint. I went with a two-toned approach to add some contrast. The colors are Stainless Steel (lighter) and Gunmetal (darker). The basic process was basically: airbrush, dry, buff, seal, mask, airbrush, dry, buff, and seal.</p>
<p><img class="alignnone  wp-image-1743" alt="Ghost Rifle - Base Paint" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-11-10-56-35-PM-1024x1024.jpg" width="553" height="553" /></p>
<p>For the tube thing on the stock, I bent a piece of 1/4&#8243; aluminum rod and placed it into the eye holes of the space chicken.</p>
<p><img class="alignnone  wp-image-1744" alt="Ghost Rifle - Bender" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-11-6-46-45-PM-1024x768.jpg" width="553" height="415" /></p>
<p>Finally I did a lot of weathering on the gun. I wanted it to look like it&#8217;s been fighting Zerg for the last decade. I used acrylic black and yellow ochre paints to get a dirty, dusty look.</p>
<p><img class="alignnone  wp-image-1745" alt="Ghost Rifle - Weathering" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-12-1-16-11-PM-768x1024.jpg" width="553" height="737" /></p>
<p>Then I added a couple of coats of matte clear spray paint and this bad boy was done! *gasp* This is, to date, my most challenging project; both technically and emotionally. Thank you for coming on this journey with me!</p>
<p><img class="alignnone  wp-image-1746" alt="Ghost Rifle - Finished" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-12-8-22-53-PM-1024x1024.jpg" width="553" height="553" /></p>
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		<slash:comments>4</slash:comments>
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		<title>Batman: Arkham City &#8211; Robin Costume</title>
		<link>http://props.punishedpixels.com/2013/03/13/batman-arkham-city-robin-costume/</link>
		<comments>http://props.punishedpixels.com/2013/03/13/batman-arkham-city-robin-costume/#comments</comments>
		<pubDate>Wed, 13 Mar 2013 20:55:41 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Costume]]></category>
		<category><![CDATA[featured]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=1646</guid>
		<description><![CDATA[I am a huge fan of the art style in the Batman: Arkham Asylum/City games and have been wanting to do a costume from them for a very long time. I may, some day, make a Batman in that style, but for now, I was more than pleased to try and tackle the Arkham City [...]]]></description>
				<content:encoded><![CDATA[<p>I am a huge fan of the art style in the Batman: Arkham Asylum/City games and have been wanting to do a costume from them for a very long time. I may, some day, make a Batman in that style, but for now, I was more than pleased to try and tackle the Arkham City Robin. It challenged both my creative skills and my fitness level!<img class="alignnone  wp-image-1649" alt="ECCC Robin Costume" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/8526816711_777713b323_z1.jpg" width="576" height="383" />Photo by <a title="http://www.flickr.com/photos/n8zim/" href="http://www.flickr.com/photos/n8zim/">Nate Zimmer</a>.</p>
<p>The most challenging part of this costume was the mask. I&#8217;ve never made a face hugging prosthetic like this before, so I had to do some learning to figure it out. I started by making a casting of my own head with plaster bandages (I had helpers).</p>
<p><img class="alignnone  wp-image-1651" alt="Robin - Face Casting" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/44696_590965274263645_2132982362_n.jpg" width="576" height="576" /></p>
<p>From that I was able to cast a plastic copy of my face. It was pretty rough, since the plaster isn&#8217;t really detailed, but I was able to sand it down nicely and use it as a base for sculpting my Robin domino mask.</p>
<p><img class="alignnone  wp-image-1652" alt="Robin - Face Cast" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-17-10-09-46-AM-1024x768.jpg" width="553" height="415" /></p>
<p>The mask was sculpted using a non-drying, non-sulfuric modeling clay. This was very similar to my <a title="http://props.punishedpixels.com/2012/12/10/borderlands-2-handsome-jack-mask/" href="http://props.punishedpixels.com/2012/12/10/borderlands-2-handsome-jack-mask/">Handsome Jack mask sculpt</a>. I took my time with this, trying really hard to get it nice and smooth, as well as symmetrical. To smooth it, I rubbed it with isopropyl alcohol a whole bunch.</p>
<p><img class="alignnone  wp-image-1653" alt="Robin - Face Sculpt 1" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-17-5-36-21-PM-1024x768.jpg" width="553" height="415" /></p>
<p><img class="alignnone  wp-image-1654" alt="Robin - Face Sculpt 2" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-18-1-26-09-PM-1024x768.jpg" width="553" height="415" />Next I had to mold this thing. I used <a title="http://www.smooth-on.com/" href="http://www.smooth-on.com/">Smooth-On&#8217;s</a> Rebound 25. It was done in several steps to get a good skin of rubber on it and then add registration keys later. Then the front got a Plasti-Paste jacket mold.</p>
<p><img class="alignnone  wp-image-1656" alt="Robin - Molding 1" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-18-3-20-28-PM-1024x768.jpg" width="553" height="415" /></p>
<p><img class="alignnone  wp-image-1657" alt="Robin - Molding 2" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-19-9-29-57-AM-1024x1024.jpg" width="553" height="553" /></p>
<p>Next I pulled the front mold off of the plastic face form. As luck would have it, the clay came right off the form and stayed in the mold. This was huge. Because of this, I had very little issue molding the back of the mask!</p>
<p><img class="alignnone  wp-image-1658" alt="Robin - Molding 3" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-19-11-38-54-AM-1024x768.jpg" width="553" height="415" /></p>
<p>Casting the mask was pretty tricky. I used a urethane rubber resin and it is rather viscous while in it&#8217;s liquid state. I did some test casts that didn&#8217;t go so great, but I ended up with a bit of a jury rigged injection molding process. I drilled two holes into the back of the mask; one to pour resin in and one as an air vent. Then I put a bunch of eye droppers into the liquid resin to suck up the material. One at a time, I inserted the eye droppers into the pouring hole and injected the resin into the mold. I repeated this until resin came out of the air vent. This way I was very sure that there were no air bubbles in the mold!</p>
<p><img class="alignnone  wp-image-1659" alt="Robin - Mask Casting" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-23-10-21-41-AM-768x1024.jpg" width="553" height="737" /></p>
<p><img class="alignnone  wp-image-1669" alt="Robin - Finished Mask" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Mar-13-12-59-22-PM.jpg" width="576" height="432" /></p>
<p>The belt was another complicated piece. I wanted to duplicate the game model, but I wasn&#8217;t concerned with the pouches being functional. I decided to model and cast the buckle and pouches from plastic. They were shaped from pieces of PCV foam plastic and cast in silicone for molding!</p>
<p><img class="alignnone  wp-image-1671" alt="Robin - Pouch" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-20-5-35-50-PM-1024x768.jpg" width="553" height="415" /></p>
<p><img class="alignnone  wp-image-1672" alt="Robin - Buckle" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-20-2-59-07-PM-1024x768.jpg" width="553" height="415" /></p>
<p>The finished pieces were cast from polyurethane plastic resin. I used a yellow tint in the resin so that the pieces wouldn&#8217;t need to be painted. The result was pretty damn close to the source material.</p>
<p><img class="alignnone  wp-image-1673" alt="Robin - Belt Castings" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-21-9-20-29-AM-1024x768.jpg" width="553" height="415" /></p>
<p>After casting and weathering the belt pieces, I attached them all to a 2&#8243; wide strip of nylon webbing. The plastic pieces were attached via screws. Also attached to the webbing was a buckle clip for easy adjustment and removal.</p>
<p><img class="alignnone  wp-image-1675" alt="Robin - Belt Pieces" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-25-9-12-52-PM-1024x768.jpg" width="553" height="415" /></p>
<p><img class="alignnone  wp-image-1674" alt="Robin - Belt Webbing" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-25-10-23-06-PM-768x1024.jpg" width="553" height="737" /></p>
<p>For the shirt, I tried to make my own shirt from scratch. It was a total disaster and all photo evidence of it has been destroyed. I ended up going with a plain red, athletic compression shirt. I stretched the shirt over a plaster casting that I have of my torso and painting it to resemble the in-game character&#8217;s shirt/armor.</p>
<p>For the painting, I drew in guide lines freehand with a fabric marker.</p>
<p><img class="alignnone  wp-image-1676" alt="Robin - Shirt Lines" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-26-11-47-11-AM-768x1024.jpg" width="553" height="737" /></p>
<p>Once everything was laid out, I used my airbrush to paint in the rest of the details. This actually went pretty quickly and I was very pleased with the results. The highlights were done with a gold paint pen. Some of the &#8220;damaged&#8221; bits were brushed on fabric paint. I also used that technique to cover the Nike Shwoosh on the upper chest.</p>
<p><img class="alignnone  wp-image-1678" alt="Robin - Shirt Painted" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-26-12-47-31-PM-768x1024.jpg" width="553" height="737" /></p>
<p>The &#8220;R&#8221; on the chest was done much like the belt pieces. It was cut from PVC foam sheets, molded and then cold cast with brass powder so that I could give it a nice, shiny polish.</p>
<p><img class="alignnone  wp-image-1683" alt="Robin - R" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-21-2-14-36-PM-1024x768.jpg" width="553" height="415" /></p>
<p>Shiny!</p>
<p><img class="alignnone  wp-image-1684" alt="Robin - Shiny R" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-22-7-58-39-PM-1024x768.jpg" width="553" height="415" /></p>
<p>The forearm and boot armor bits were all made from EVA foam floor mats. The technique here was identical to my <a title="http://props.punishedpixels.com/2012/08/28/mass-effect-n7-defender-armor/" href="http://props.punishedpixels.com/2012/08/28/mass-effect-n7-defender-armor/">N7 Defender armor build</a>. The foam parts were heated with a heat gun and formed over a large PVC pipe.</p>
<p><img class="alignnone  wp-image-1679" alt="Robin - Forearm Armor" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-25-10-53-24-AM-1024x768.jpg" width="553" height="415" /></p>
<p>For the boots, I made foam coverings for a pair of boots that I already owned. The gloves were shop gloves from Harbor Freight that I cut the finger tips off of. With everything assembled, everything got some touch up weathering paint.</p>
<p><img class="alignnone  wp-image-1681" alt="Robin - Armor" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-26-12-06-53-AM-1024x768.jpg" width="553" height="415" /></p>
<p>The weapon is hand down the easiest prop I&#8217;ve ever made. It&#8217;s a stick. I built it from two pieces of dowel and a PVC pipe. Then I painted lines on it. Done.</p>
<p><img class="alignnone  wp-image-1682" alt="Robin - Stick" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-27-11-19-36-AM-768x1024.jpg" width="553" height="737" /></p>
<p>The last thing I made was the hood and cape. It&#8217;s all one piece, sewn from one piece of black and one piece of yellow cloth. It took me a lot of trial, error, and swearing to get it to fit properly, but it eventually came together. It attaches at the throat with a snap.</p>
<p><img class="alignnone  wp-image-1686" alt="Robin - Cape" src="http://props.punishedpixels.com/wp-content/uploads/2013/03/Photo-Feb-26-7-02-18-PM-768x1024.jpg" width="553" height="737" /></p>
<p>That&#8217;s it! All done! I wore this get-up to Emerald City Comic Con a couple of weeks ago and it was a hit! I high-fived at least 30 other Robins. Win!</p>
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		<slash:comments>5</slash:comments>
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		<item>
		<title>Queen&#8217;s Blade &#8211; Risty&#8217;s Spiked Mace &amp; Shield</title>
		<link>http://props.punishedpixels.com/2013/02/08/queens-blade-ristys-spiked-mace-shield/</link>
		<comments>http://props.punishedpixels.com/2013/02/08/queens-blade-ristys-spiked-mace-shield/#comments</comments>
		<pubDate>Fri, 08 Feb 2013 20:10:47 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Prop]]></category>
		<category><![CDATA[featured]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=1017</guid>
		<description><![CDATA[Back in December, I got a messaged from famed cosplayer Jessica Nigri about the possibility of getting a mace and shield build for an upcoming costume of hers. Of course I jumped at the chance to make a set of weapons that are so EPIC! This build was a pretty big departure from my traditional [...]]]></description>
				<content:encoded><![CDATA[<p>Back in December, I got a messaged from famed cosplayer <a title="https://www.facebook.com/OfficialJessicaNigri?fref=ts" href="https://www.facebook.com/OfficialJessicaNigri?fref=ts">Jessica Nigri</a> about the possibility of getting a mace and shield build for an upcoming costume of hers. Of course I jumped at the chance to make a set of weapons that are so EPIC!</p>
<p><a href="http://props.punishedpixels.com/wp-content/uploads/2013/02/risty_finished.jpg"><img class="alignnone  wp-image-1100" alt="Risty Finished" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/risty_finished.jpg" width="540" height="358" /></a></p>
<p>This build was a pretty big departure from my traditional space pistols and daggers, so I did a LOT of planning! I knew that it needed to be durable for convention usage as well as fairly light weight. I spent a day or two drawing up some extremely detailed blueprints.</p>
<p><img class="alignnone size-large wp-image-1020" title="Risty Blueprints" alt="Risty Blueprints" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Dec-24-9-36-43-AM-1024x768.jpg" width="560" height="420" /></p>
<p>The dome shape of the mace was built out of 8&#8243; acrylic light globes from Home Depot. I got two of them incase I broke one and I needed some spare material to account for the light fixture lip on the bottom of the dome.</p>
<p><img class="alignnone size-large wp-image-1021" title="Risty Domes" alt="Risty Domes" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Dec-23-4-18-07-PM-1024x768.jpg" width="560" height="420" /></p>
<p>The spikes were molded and I lathed the master from plastic resin that was originally cast out of a funnel to save on materials and lathing time. I needed 13 of them for the whole mace. One of the trickier parts of build was figuring out the spacing on the dome for all of those spikes. Also tricky: not bashing a hole through the acrylic sphere while drilling holes for the spikes.</p>
<p><img class="alignnone size-large wp-image-1023" title="Risty Spike Master" alt="Risty Spike Master" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Dec-29-4-50-24-PM-1024x768.jpg" width="560" height="420" /></p>
<p>I started the shield shape by making a cross section from MDF wood and filling in the quadrants with rigid insulation foam. The shape was then cut with a coping saw, carved with a rasp, and sanded.</p>
<p><img class="alignnone size-large wp-image-1025" title="Risty Quadrants" alt="Risty Quadrants" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-05-11-26-47-AM-1024x768.jpg" width="560" height="420" /></p>
<p><img class="alignnone size-large wp-image-1026" title="Risty Shield Shaped" alt="Risty Shield Shaped" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-07-9-49-47-PM-1024x768.jpg" width="560" height="420" /></p>
<p>Then I coated the shield shape in several coats of polyurethane plastic resin. These layers of plastic got sanded, shaped, and filled with Bondo until I had a form that I was happy with.</p>
<p><img class="alignnone size-large wp-image-1027" title="Risty Resin Coats" alt="Risty Resin Coats" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-08-3-00-27-PM-1024x768.jpg" width="560" height="420" /></p>
<p><img class="alignnone size-large wp-image-1028" title="Risty Shield Bondo" alt="Risty Shield Bondo" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-08-10-07-48-PM-1024x768.jpg" width="560" height="420" /></p>
<p>After the shield dome shape was good, I cut out the outer lip of the shield, also from insulation foam. This was glued to the inner dome and also skinned in resin, sanded, and filled.</p>
<p><img class="alignnone size-large wp-image-1029" title="Risty Shield Lip" alt="Risty Shield Lip" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-08-10-36-06-PM-1024x1024.jpg" width="560" height="560" /></p>
<p><img class="alignnone size-large wp-image-1030" title="Risty Shield Lip Resin" alt="Risty Shield Lip Resin" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-09-11-26-39-AM-1024x768.jpg" width="560" height="420" /></p>
<p>The cross pieces of the shield were cut from varying thicknesses of foam PVC. The center circle piece was 1/4&#8243; thick and glued down to the center. The cross strips were 1/8&#8243; thick and were heat formed to the contour of the shield. These were also glued down. At this point I was feeling particularly badass.</p>
<p><img class="alignnone size-large wp-image-1033" title="Risty Badass" alt="Risty Badass" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-09-7-15-58-PM1-768x1024.jpg" width="560" height="746" /></p>
<p>Since this shield needed to be lightweight and durable, I decided to vacuform it from high impact styrene. That meant that I needed a new vacuform table!</p>
<p><img class="alignnone size-large wp-image-1034" title="Risty Buck" alt="Risty Buck" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-10-8-24-31-PM-1024x768.jpg" width="560" height="420" /></p>
<p><img class="alignnone size-large wp-image-1035" title="Risty Vacuformed" alt="Risty Vacuformed" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-11-4-12-33-PM-1024x768.jpg" width="560" height="420" /></p>
<p>The shield handle was made from some PVC pipe and pipe fixtures. The yellow bit on the pommel end is more polyurethane plastic resin that I cast on the end of the tube and spun around the lathe. All of the back side of the shield was attached to a circle of 1/4&#8243; MDF wood. The planks on the back were also 1/4&#8243; MDF that I carved some grain lines in with my Dremel. I put T-nuts in the back piece for attaching the strap and handle later.</p>
<p><a href="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-12-4-51-30-PM.jpg"><img class="alignnone size-large wp-image-1036" title="Risty Shield Handle" alt="Risty Shield Handle" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-12-4-51-30-PM-1024x768.jpg" width="560" height="420" /></a></p>
<p><img class="alignnone size-large wp-image-1037" title="Risty Shield Back" alt="Risty Shield Back" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-13-6-02-25-PM-1024x768.jpg" width="560" height="420" /></p>
<p>With the mold made for the mace spikes, I slush cast them from plastic resin, adding a bold with the last layer. This way the spikes could be bolted into the dome head.</p>
<p><img class="alignnone size-large wp-image-1039" title="Risty Spike Mold" alt="Risty Spike Mold" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-12-7-05-42-PM-1024x768.jpg" width="560" height="420" /></p>
<p><img class="alignnone size-large wp-image-1040" title="Risty Spike Bolt" alt="Risty Spike Bolt" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-13-1-28-24-PM-1024x1024.jpg" width="560" height="560" /></p>
<p>All 13 of the spikes were bolted into the dome. (Not pictured: The interior of the dome was reinforced with fiberglass and then after the nuts were tightened I slush cast plastic resin to reinforce the shape more as well as keep the nuts from spinning off.) (Pictured: Total Badass)</p>
<p><img class="alignnone size-full wp-image-1041" title="Risty Spike Hand" alt="Risty Spike Hand" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-14-6-16-59-PM.jpg" width="480" height="640" /></p>
<p>Suddenly I realized that the deadline was looming, so I didn&#8217;t take very many photos, but I will do my best to paint you a word picture.</p>
<ul>
<li>The shaft is a 1-1/8&#8243; wooden dowel. The hexagon shape was achieved with a belt sander.</li>
<li>The small collar on the top of the shaft was two pieces of 1/4&#8243; MDF with 4 faceted pieces of styrene.</li>
<li>The tapered cone thing near the top of the shaft is polyurethane plastic resin that was cast around a PVC tube and turned on the lathe.</li>
<li>All of this stuff was glued to the dome.</li>
</ul>
<p><img class="alignnone size-large wp-image-1042" title="Risty Spike Assembly" alt="Risty Spike Assembly" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-15-9-20-47-PM-1024x768.jpg" width="560" height="420" /></p>
<p>The pommel of the spike was also a lathed piece of plastic resin that was bolted into the bottom of the shaft. All of the rivet pieces on both the mace and shield were furniture tacks. The screw pieces on the shield were cast plastic from a simple clay push mold. The deadline was looming at this point! GET IT PRIMED!</p>
<p><img class="alignnone size-large wp-image-1043" title="Risty Primed" alt="Risty Primed" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-17-6-22-37-PM-1024x768.jpg" width="560" height="420" /></p>
<p>Most of the metal looking parts on the mace were painted with an airbrush &#8220;metalizer&#8221; lacquer. After spraying it, I buffed it with a cloth and it looks wicked awesome.</p>
<p><img class="alignnone size-large wp-image-1047" title="Risty Metalizer" alt="Risty Metalizer" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-18-5-46-17-PM-1024x768.jpg" width="560" height="420" /></p>
<p>After that, everything got painted. I also didn&#8217;t take any photos here, but most of it was masking, rattle cans, clear coats, and then weathering!</p>
<p><img class="alignnone size-large wp-image-1048" title="Risty Painted" alt="Risty Painted" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-20-10-31-15-PM-1024x768.jpg" width="560" height="420" /></p>
<p>The back of the shield got a repurposed leather belt as a strap and voila! It is done!</p>
<p><img class="alignnone size-large wp-image-1049" title="Risty Strapped" alt="Risty Strapped" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-21-4-50-13-PM-768x1024.jpg" width="560" height="746" /></p>
<p>Total. Badass.</p>
<p><img class="alignnone size-large wp-image-1050" title="Total Badass" alt="Total Badass" src="http://props.punishedpixels.com/wp-content/uploads/2013/02/Photo-Jan-21-7-03-36-PM-768x1024.jpg" width="560" height="746" /></p>
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		<slash:comments>4</slash:comments>
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		<item>
		<title>Borderlands 2 &#8211; Handsome Jack Mask</title>
		<link>http://props.punishedpixels.com/2012/12/10/borderlands-2-handsome-jack-mask/</link>
		<comments>http://props.punishedpixels.com/2012/12/10/borderlands-2-handsome-jack-mask/#comments</comments>
		<pubDate>Mon, 10 Dec 2012 16:58:18 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Costume]]></category>
		<category><![CDATA[Prop]]></category>
		<category><![CDATA[featured]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=807</guid>
		<description><![CDATA[Greetings Vault Hunters! I had the good fortune of being commissioned to build the mask of this wonderful hero from Borderlands 2! Handsome Jack! I took my references straight from the in-game model and a 2D mask image that Gearbox provided as a cut-out, flat mask. As is my traditional style, I took several orthographic [...]]]></description>
				<content:encoded><![CDATA[<p>Greetings Vault Hunters! I had the good fortune of being commissioned to build the mask of this wonderful hero from Borderlands 2! Handsome Jack!</p>
<p><img class="alignnone size-large wp-image-810" title="Handsome Jack - Beauty Shot" alt="Handsome Jack - Beauty Shot" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/DSC_3865-1024x678.jpg" width="560" height="370" /></p>
<p>I took my references straight from the in-game model and a 2D mask image that Gearbox provided as a cut-out, flat mask. As is my traditional style, I took several orthographic views and drew up nice, concise vectors.</p>
<p><a href="http://www.flickr.com/photos/doranwa/8185253156/sizes/o/in/photostream/"><img class="alignnone size-large wp-image-812" title="Handsome Jack - Vectors" alt="Handsome Jack - Vectors" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/HJ_vector-1024x548.jpg" width="560" height="299" /></a></p>
<p>I had ideas for making more than one copy of this guy, so I planned accordingly. The aim was to create a master that I could make a mold from. I sculpted the face out of modeling clay on top of a foam mannequin head.</p>
<p><img class="alignnone size-large wp-image-811" title="Handsome Jack - Prep" alt="Handsome Jack - Prep" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-13-12-46-31-PM-768x1024.jpg" width="560" height="746" /></p>
<p>The modeling clay works best when it&#8217;s nice and warm, so I kept it in a box with a desk lamp pointed at it. Then I took large hunks of it and slapped it onto the foam head to get the general shape of the mask.</p>
<p><img class="alignnone size-large wp-image-814" title="Handsome Jack - Lumpy" alt="Handsome Jack - Lumpy" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-13-2-12-30-PM-768x1024.jpg" width="560" height="746" /></p>
<p>I had to dig deep into my high school art class memories to get a feel for modeling with clay again. This was definitely a test of my patience. Also, I didn&#8217;t have any clay modeling tools, so I made some.</p>
<p><img class="alignnone size-large wp-image-815" title="Handsome Jack - Shaping Up" alt="Handsome Jack - Shaping Up" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-13-6-47-19-PM-768x1024.jpg" width="560" height="746" /></p>
<p><img class="alignnone size-large wp-image-816" title="Handsome Jack - Tools" alt="Handsome Jack - Tools" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Dec-10-8-02-59-AM-768x1024.jpg" width="560" height="746" /></p>
<p>I crafted the hardware bits of the mask out of plastic and dowels. This was way easier than trying to get these hard geometric shapes out of clay. Once these pieces were finished, they were embedded straight into the clay face.</p>
<p><img class="alignnone size-large wp-image-817" title="Handsome Jack - Hardware" alt="Handsome Jack - Hardware" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-14-12-52-27-PM-1024x768.jpg" width="560" height="420" /></p>
<p><img class="alignnone size-large wp-image-818" title="Handsome Jack - Hardware Embedded" alt="Handsome Jack - Hardware Embedded" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-14-4-11-57-PM-768x1024.jpg" width="560" height="746" /></p>
<p><img class="alignnone size-large wp-image-819" title="Handsome Jack - Hardware Embedded Face" alt="Handsome Jack - Hardware Embedded Face" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-16-5-31-29-PM-768x1024.jpg" width="560" height="746" /></p>
<p>With the sculpting finished, it was time for this guy to go under some silicone. I used Smooth-On&#8217;s Rebound 25. He got 3-4 layers of silicone. Half way through I added some registration keys for the mold jacket.</p>
<p><img class="alignnone size-large wp-image-821" title="Handsome Jack - Siliconed" alt="Handsome Jack - Siliconed" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-20-1-19-14-PM-1024x1024.jpg" width="560" height="560" /></p>
<p><img class="alignnone size-large wp-image-822" title="Handsome Jack - Registration Keys" alt="Handsome Jack - Registration Keys" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-20-9-28-50-PM-768x1024.jpg" width="560" height="746" /></p>
<p>2 layers of Plasti-Paste made up the mold jacket.</p>
<p><img class="alignnone size-large wp-image-823" title="Handsome Jack - Jacket" alt="Handsome Jack - Jacket" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-21-8-10-54-AM-1024x768.jpg" width="560" height="420" /></p>
<p>Once all of this was cured, I pulled it all off the master. The clay came off with the silicone, destroying the master. Let&#8217;s hope the mold works, or a week of sculpting will have just gone right out the window!</p>
<p><img class="alignnone size-large wp-image-824" title="Handsome Jack - Ripped Apart" alt="Handsome Jack - Ripped Apart" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-21-9-48-34-AM-768x1024.jpg" width="560" height="746" /></p>
<p>VIOLA!</p>
<p><img class="alignnone size-large wp-image-825" title="Handsome Jack - Finished Mold" alt="Handsome Jack - Finished Mold" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-21-10-08-48-AM-768x1024.jpg" width="560" height="746" /></p>
<p>The copies were slush cast with polyurethane plastic resin. Pictured here is Tap Plastic&#8217;s Quik Cast, but I ended up using Smooth-On&#8217;s Smooth-Cast 300. For a comprehensive tutorial on slush casting, check out <a title="http://www.youtube.com/watch?v=cZTdZZj417g" href="http://www.youtube.com/watch?v=cZTdZZj417g">Volpin Props&#8217; video here</a>.</p>
<p><img class="alignnone size-large wp-image-826" title="Handsome Jack - Slush Casting" alt="Handsome Jack - Slush Casting" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Nov-27-4-31-38-PM-768x1024.jpg" width="560" height="746" /></p>
<p>Out of the mold, the mask looks pretty decent, but needs a lot of sanding. I had a lot of trouble getting the master to be perfectly smooth since you can&#8217;t sand clay.</p>
<p><img class="alignnone size-large wp-image-828" title="Handsome Jack - Pull" alt="Handsome Jack - Pull" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Dec-04-6-15-47-PM-768x1024.jpg" width="560" height="746" /></p>
<p>Post sanding, this handsome fellow was ready for a little paint. The base coat was some light, flesh colored enamels that I applied with my airbrush. I also went over the face again with a slightly darker skin tone to give it a little depth. The hair and metal bits were also enamels that I just brushed on. I outlined his face, as per the game art style, with permanent marker.</p>
<p><img class="alignnone size-large wp-image-829" title="Handsome Jack - Base Coat" alt="Handsome Jack - Base Coat" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Dec-05-9-29-53-PM-768x1024.jpg" width="560" height="746" /></p>
<p><img class="alignnone size-large wp-image-830" title="Handsome Jack - Outlines" alt="Handsome Jack - Outlines" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/Photo-Dec-06-2-58-07-PM-1024x1024.jpg" width="560" height="560" /></p>
<p>Finally, the client asked that I add removable eyes for display purposes. So here is our cheeky hero, complete with peepers!</p>
<p><img class="alignnone  wp-image-831" title="Handsome Jack - Finished" alt="Handsome Jack - Finished" src="http://props.punishedpixels.com/wp-content/uploads/2012/12/jack_face.jpg" width="504" height="672" /></p>
]]></content:encoded>
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		<slash:comments>22</slash:comments>
		</item>
		<item>
		<title>The Elderscrolls: Skyrim &#8211; Keening</title>
		<link>http://props.punishedpixels.com/2012/11/06/keening/</link>
		<comments>http://props.punishedpixels.com/2012/11/06/keening/#comments</comments>
		<pubDate>Tue, 06 Nov 2012 21:01:56 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Prop]]></category>
		<category><![CDATA[featured]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=698</guid>
		<description><![CDATA[I finally got a commission to build this amazing piece from Skyrim! In order to get good reference images of Keening, I decided the best thing to do was to play Skyrim and acquire the in-game item. 10 hours of gameplay later (I got a little sidetracked) and voila! I had the dagger! I grabbed [...]]]></description>
				<content:encoded><![CDATA[<p>I finally got a commission to build this amazing piece from Skyrim!</p>
<p><img class="alignnone size-large wp-image-702" title="Keening - FInished" alt="Keening - FInished" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/DSC_3737-1024x678.jpg" width="560" height="370" /></p>
<p>In order to get good reference images of Keening, I decided the best thing to do was to play Skyrim and acquire the in-game item. 10 hours of gameplay later (I got a little sidetracked) and voila! I had the dagger! I grabbed some snapshots of the screen and drew up my own schematics.</p>
<p><img class="alignnone size-full wp-image-704" title="Keening - Reference" alt="Keening - Reference" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/keening_ortho.jpg" width="353" height="854" /></p>
<p><img class="alignnone size-large wp-image-705" title="Keening - Vector" alt="Keening - Vector" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/skyrim_keeing_vector-394x1024.jpg" width="394" height="1024" /></p>
<p>I started out by turning the handle on my lathe out of a cylinder of polyurethane resin that was cast in a toilet paper tube. The side spike things were also lathed from plastic.</p>
<p><img class="alignnone size-full wp-image-707" title="Keening - Handle" alt="Keening - Handle" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-23-1-36-06-PM.jpg" width="640" height="480" /></p>
<p><img class="alignnone size-full wp-image-708" title="Keening - Spikes" alt="Keening - Spikes" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-31-2-20-45-PM.jpg" width="640" height="480" /></p>
<p>The bottom wing-a-ling pieces of the pommel were shaped out with PVC and styrene, then filled in and sculpted with Apoxie Sculpt. The rectangular holes at the top of the handle were cut from a strip of styrene, which was heated and bent around the handle.</p>
<p><img class="alignnone size-full wp-image-714" title="Keening - Handle Detail" alt="Keening - Handle Detail" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-23-6-21-24-PM.jpg" width="640" height="480" /></p>
<p>The hilt pieces and the crystal were both made from 3/8&#8243; thick foam PVC sheet. The &#8220;skeleton&#8221; shape pieces were cut from thin styrene and glued to the PVC.</p>
<p><img class="alignnone size-full wp-image-709" title="Keening - Hilt" alt="Keening - Hilt" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-24-3-44-04-PM.jpg" width="640" height="480" /></p>
<p><img class="alignnone size-full wp-image-710" title="Keening - Crystal" alt="Keening - Crystal" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-24-12-34-51-PM.jpg" width="640" height="480" /></p>
<p>The empty spaces of the skeletons were filled in with Bondo and shaped on a belt sander/Dremel. Also the circular piece on the hilt was lathed from plastic and copied in a clay push mold. The metal detail pieces on the hilt are the heads of rivets that were cut down and glued in place.</p>
<p><img class="alignnone size-full wp-image-711" title="Keening - Bondo" alt="Keening - Bondo" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-30-5-29-17-PM.jpg" width="640" height="480" /></p>
<p>The sides of the hilt were done similarly, but from just the thin styrene.</p>
<p><img class="alignnone size-full wp-image-712" title="Keening - Hilt Side" alt="Keening - Hilt Side" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-31-3-20-32-PM.jpg" width="640" height="480" /></p>
<p>More detail bits were added to the side pieces with styrene. I also drilled holes into the side pieces to accept the side spike things (not pictured).</p>
<p><img class="alignnone size-full wp-image-713" title="Keening - Hilt Side Details" alt="Keening - Hilt Side Details" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-31-5-19-44-PM.jpg" width="480" height="640" /></p>
<p>The cross piece that bridges the two side hilt pieces was made from a flat piece of PVC sheet and styrene. The plan is to cast it flat and then bend it around the crystal while the resin is still pliable.</p>
<p><img class="alignnone size-full wp-image-716" title="Keening - Cross Piece" alt="Keening - Cross Piece" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-31-6-49-29-PM.jpg" width="480" height="640" /></p>
<p>The metal detail bits on the side hilt pieces are furniture tacks that I sanded down to size and glued down. With all of the pieces done, I put them in clay for molding!</p>
<p><img class="alignnone  wp-image-717" title="Keening - Pieces Done" alt="Keening - Pieces Done" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/keening04.jpg" width="576" height="768" /></p>
<p><img class="alignnone size-large wp-image-718" title="Keening - Clayed" alt="Keening - Clayed" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Nov-02-5-33-44-PM-1024x768.jpg" width="560" height="420" /></p>
<p>Cut to two days later and the silicone molds are done! The plan is to cold cast the pieces in plastic resin with bronze powder.</p>
<p><img class="alignnone  wp-image-719" title="Keening - Molds" alt="Keening - Molds" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/keening03.jpg" width="576" height="432" /></p>
<p>Here are a couple of cold cast pieces, one that has been buffed with 00 steel wool and one that has not.</p>
<p><img class="alignnone size-large wp-image-720" title="Keening - Cold Cast" alt="Keening - Cold Cast" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Nov-04-12-37-04-PM-768x1024.jpg" width="560" height="746" /></p>
<p>The crystal was cast from Tap Plastic&#8217;s Clear-Lite resin with some green and blue transparent tint added. It took nearly 2 days to fully cure, and the outer layer remained rather tacky and hard to sand, but once I got through, that it buffed up quite nicely.</p>
<p><img class="alignnone  wp-image-721" title="Keening - Crystal" alt="Keening - Crystal" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/keening02.jpg" width="576" height="768" /></p>
<p>With all of the pieces cast and buffed, it was time for assembly! Some screws were added to add support to where the side pieces attach to the crystal. Those screws will be obscured by the cross piece. I also put a 1/4&#8243; threaded rod through the hilt that goes all the way from the handle piece to the crystal.</p>
<p><img class="alignnone size-large wp-image-722" title="Keening - Assembly" alt="Keening - Assembly" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Nov-05-3-32-36-PM-1024x768.jpg" width="560" height="420" /></p>
<p>Final assembly!</p>
<p><img class="alignnone  wp-image-723" title="Keening - Assembled" alt="Keening - Assembled" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/keening01.jpg" width="576" height="768" /></p>
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		<item>
		<title>DotA 2 &#8211; Juggernaut Mask</title>
		<link>http://props.punishedpixels.com/2012/11/06/dota-2-juggernaut-mask/</link>
		<comments>http://props.punishedpixels.com/2012/11/06/dota-2-juggernaut-mask/#comments</comments>
		<pubDate>Tue, 06 Nov 2012 18:44:13 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Costume]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=676</guid>
		<description><![CDATA[I was commissioned to build a wearable mask of the Juggernaut from DotA 2! I figured that the game art was a pretty good place to start for references, so I did most of my work from this image here. I decided that this would be an excellent chance for me to try out Pepakura [...]]]></description>
				<content:encoded><![CDATA[<p>I was commissioned to build a wearable mask of the Juggernaut from DotA 2!</p>
<p><img class="alignnone size-large wp-image-692" title="Juggernaut Mask - Finished" alt="Juggernaut Mask - Finished" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-03-2-00-03-PM-1024x768.jpg" width="560" height="420" /></p>
<p>I figured that the game art was a pretty good place to start for references, so I did most of my work from this image here.</p>
<p><img class="alignnone size-full wp-image-679" title="Juggernaut Mask - Reference" alt="Juggernaut Mask - Reference" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/juggernaut.png" width="496" height="440" /></p>
<p>I decided that this would be an excellent chance for me to try out Pepakura for the first time. I dusted off my 3D modeling skills and made a rough likeness of the mask in Maya. I used my own head for scale, because I figured that if it could fit on my giant melon head, it would fit on nearly anyone else&#8217;s head.</p>
<p><img class="alignnone  wp-image-680" title="Juggernaut Mask - Modeled" alt="Juggernaut Mask - Modeled" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/juggernaut_model.jpg" width="596" height="502" /></p>
<p>The .obj of the model was plugged into <a href="http://www.tamasoft.co.jp/pepakura-en/">Pepakura Designer</a> and I unfolded the thing. If you&#8217;d like to see how that&#8217;s done, just to a search on YouTube, there are loads of videos detailing it.</p>
<p>Once I had the Pepakura files all laid out, I printed them on heavy card stock, cut them out, and glued all of them together. Then the back side of the mask got some MDF and styrene supports.</p>
<p><img class="alignnone size-large wp-image-683" title="Juggernaut Mask - Assembled" alt="Juggernaut Mask - Assembled" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Sep-23-2-45-33-PM-1024x768.jpg" width="560" height="420" /></p>
<p><img class="alignnone size-large wp-image-684" title="Juggernaut Mask - Supports" alt="Juggernaut Mask - Supports" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Sep-23-2-45-42-PM-1024x768.jpg" width="560" height="420" /></p>
<p>To start giving the mask a bit of rigidity, I slathered the outside surface in fiberglass resin. Once that hardened, the back side got the full fiberglass treatment!</p>
<p><img class="alignnone size-large wp-image-686" title="Juggernaut Mask - Goo" alt="Juggernaut Mask - Goo" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Sep-23-4-46-48-PM-1024x768.jpg" width="560" height="420" /></p>
<p><img class="alignnone size-large wp-image-687" title="Juggernaut Mask - Glassed" alt="Juggernaut Mask - Glassed" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Sep-24-12-09-21-PM-1024x768.jpg" width="560" height="420" /></p>
<p>Now that the mask was all kinds of stiff, I faired out the faceted faces with a whole lot of Bondo.</p>
<p><img class="alignnone size-large wp-image-688" title="Juggernaut Mask - Bondo" alt="Juggernaut Mask - Bondo" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Sep-25-5-52-03-PM-1024x768.jpg" width="560" height="420" /></p>
<p>Up until now our Juggernaut was blind! I went ahead and gave him some eye holes. You&#8217;ll also notice that the mask has been sanded a whole lot and is nice and smooth compared to the faceted look it had from the Pepakura process.</p>
<p><img class="alignnone  wp-image-689" title="Juggernaut Mask - Eye Holes" alt="Juggernaut Mask - Eye Holes" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Sep-26-2-58-13-PM.jpg" width="576" height="432" /></p>
<p>Finally this bad boy got some paint! It was sprayed with an off-white enamel and clear coated. Then the red lines were hand painted on with some more enamels. Tah-dah! I also added some foam and elastic to the back side of the mask so that it could be worn.</p>
<p><img class="alignnone  wp-image-693" title="Juggernaut Mask - Painted" alt="Juggernaut Mask - Painted" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-01-3-59-21-PM.jpg" width="576" height="432" /></p>
<p><img class="alignnone size-large wp-image-694" title="Juggernaut Mask - Foam Elastic" alt="Juggernaut Mask - Foam Elastic" src="http://props.punishedpixels.com/wp-content/uploads/2012/11/Photo-Oct-03-2-00-41-PM-1024x768.jpg" width="560" height="420" /></p>
<p>That&#8217;s it, all done!</p>
<p>&nbsp;</p>
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		<title>Diablo III &#8211; Demon Hunter</title>
		<link>http://props.punishedpixels.com/2012/09/05/diablo-iii-demon-hunter/</link>
		<comments>http://props.punishedpixels.com/2012/09/05/diablo-iii-demon-hunter/#comments</comments>
		<pubDate>Wed, 05 Sep 2012 01:10:23 +0000</pubDate>
		<dc:creator>PunishedProps</dc:creator>
				<category><![CDATA[Blogs]]></category>
		<category><![CDATA[Costume]]></category>
		<category><![CDATA[Prop]]></category>

		<guid isPermaLink="false">http://props.punishedpixels.com/?p=554</guid>
		<description><![CDATA[Back in March, when I was on an episode of GameOn, my friend Veronica Belmont insisted that I make her a costume for Dragon*Con. So I did. She is a Demon Hunter from Diablo III, sporting a pistol crossbow! We kept the project under wraps during construction, so photos are a bit sparse, but I&#8217;ll [...]]]></description>
				<content:encoded><![CDATA[<p>Back in March, when I was on an episode of <a href="http://www.youtube.com/watch?v=WsecZsk0-68">GameOn</a>, my friend <a href="http://www.veronicabelmont.com/">Veronica Belmont</a> insisted that I make her a costume for Dragon*Con. So I did.</p>
<p><img class="alignnone  wp-image-557" title="Demon Hunter - Finished" alt="Demon Hunter - Finished" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Sep-03-9-47-29-AM.jpg" width="509" height="768" /></p>
<p>She is a Demon Hunter from Diablo III, sporting a pistol crossbow! We kept the project under wraps during construction, so photos are a bit sparse, but I&#8217;ll do what I can to explain the build.</p>
<p>The pistol crossbow was made form 4 layers of 3/4&#8243; pine that were adhered with wood glue. The profile shape of the middle two layers was cut out with a scroll saw before the two additional layers at the nose of the bow were added. Nuts were glued in place at the nose to attach the cross piece later.</p>
<p>The entire thing was stained and holes were drilled to accept all of the hardware pieces later. I cut a groove in the butt of the handle to paint later and create the illusion that the end is capped in a metal piece.</p>
<p><img class="alignnone size-large wp-image-558" title="Demon Hunter - Step 1" alt="Demon Hunter - Step 1" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-20-10-59-16-PM-1024x768.jpg" width="560" height="420" /></p>
<p>The cross piece was made from 1/4&#8243; foam PVC, heated and curved to my liking. The two spikes coming out of the front are both cool looking and serve to attach the cross piece to the stock. The cross piece can be removed for travel.</p>
<p>The rest of the &#8220;metal&#8221; hardware is styrene and PVC that has been painted with metallic paint. The hardware pieces were nailed and epoxied into place. The cross decorations were sculpted in Sculpy and copied by making a clay push mold and cast in polyurethane resin.</p>
<p><img class="alignnone size-large wp-image-560" title="Demon Hunter - Step 2" alt="Demon Hunter - Step 2" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-21-3-46-11-PM-1024x768.jpg" width="560" height="420" /></p>
<p>All of the armor pieces were made from EVA foam floor mats. Yes, the same ones from my Mass Effect armor that I got at the hardware store for super cheap. I had to heat and bend the foam into some rather unnatural shapes. Most of the seams were covered in thinner EVA craft foam, because they were hideous. The rest of the embellishments on the armor were done with the same craft foam, so you can&#8217;t even tell that the seams were there. Also pictured: corned beef sandwich. It was delicious.</p>
<p><img class="alignnone size-large wp-image-561" title="Demon Hunter - Step 3" alt="Demon Hunter - Step 3" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-23-11-39-58-AM-1024x768.jpg" width="560" height="420" /></p>
<p>I knew I would be putting a lot of paint on these armor pieces, so I sealed them up really well with 2-3 layers of Mod Podge. Then everything got several coats of paint via my airbrush. The darker areas were also airbrushed, then I hand brushed over the seams/embellishments with the lighter color to make them really stand out.</p>
<p><img class="alignnone size-large wp-image-562" title="Demon Hunter - Step 4" alt="Demon Hunter - Step 4" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-26-8-23-22-AM-768x1024.jpg" width="560" height="746" /></p>
<p>The boots are really just shin covers that were designed to go over a normal pair of shoes. They were created with the thinner EVA craft foam. They Velcro up the back while wearing. In this next photo you can still see some of the Mod Podge that hasn&#8217;t dried yet. I realize that the foam colors don&#8217;t match, but these got covered in paint, so no foul.</p>
<p><img class="alignnone size-large wp-image-563" title="Demon Hunter - Step 5" alt="Demon Hunter - Step 5" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-26-9-01-59-PM-768x1024.jpg" width="560" height="746" /></p>
<p>The corset part was also done in thin craft foam and painted to look like leather with straps and buckles. It has a 2&#8243; wide nylon strap around the waist to attach it to the wearer and several other strategic Velcro bits. In fact, all of these pieces were attached to the under shirt via strategic Velcro bits. I played bass for Strategic Velcro Bits.</p>
<p><img class="alignnone size-large wp-image-564" title="Demon Hunter - Step 6" alt="Demon Hunter - Step 6" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-27-9-33-03-PM-1024x768.jpg" width="560" height="420" /></p>
<p>This is one of my favorite beers; Full Sail LTD. It&#8217;s awesome and I put a cocktail parasol in it. This was cracked open when I finished all of the armor bits as a tiny celebration. Basically, I found this photo on my phone and just wanted to share it with you.</p>
<p><img class="alignnone size-large wp-image-565" title="Beer" alt="Beer" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-28-10-29-17-PM-768x1024.jpg" width="560" height="746" /></p>
<p>The pants were done entirely in fabric paint markers. The base is a pair of dark gray women&#8217;s athletic pants. All of the details were drawn on by hand. It turns out all of those geeky art classes paid off. Suck it jocks.</p>
<p><img class="alignnone size-large wp-image-566" title="Demon Hunter - Step 7" alt="Demon Hunter - Step 7" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-29-12-51-29-PM-768x1024.jpg" width="560" height="746" /></p>
<p>Finally, here are all of the pieces of the costume, laid out on the floor. I sewed up a hood/cape from linen and sewed a bunch of Velcro onto a brown shirt to be used to attach all of the armor bits to the wearer&#8217;s torso. Also there are some gloves. I think I found them at a costume store, but I can&#8217;t be sure because that was like 2 days before Dragon*Con and I was delirious.</p>
<p><img class="alignnone size-large wp-image-567" title="Demon Hunter - Step 8" alt="Demon Hunter - Step 8" src="http://props.punishedpixels.com/wp-content/uploads/2012/09/Photo-Aug-29-5-55-05-PM-768x1024.jpg" width="560" height="746" /></p>
<p>&nbsp;</p>
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