When the shop vac is plugged into the fitting and turned on, it sucks the acrylic into the holes. To make the helmet lenses, a tinted piece of acrylic was cut to shape on the scroll saw, heated in a toaster oven until it's soft and floppy, then placed over the eye holes in the box. The box was fitted with a shop vac attachment like so: I learned a lot along the way and I'm still proud of the end result all these years later:īecause I wanted these helmets to have custom-formed, bubble-shaped, tinted lenses, I made up a vacforming contraption that would form heated acrylic to shape:Īll it was was a slightly too thick cast of the eye hole area of the helmet that was cut out and built into a nearly airtight wooden box. The hand sculpted master was molded in silicone and rotocast in urethane resin. I used to build and paint the miniatures when I was a kid and this seemed like a fun project. In a way, they started way back when I just started tinkering with prop making as a hobby, I sculpted out a lifesize version of one of an old-school "beaky" Space Marine helmet. These particular helmets have a fun history. If you want to see all of the various processes, tools, and convoluted thinking that went into making them, read on. A while back someone asked me if I 3D print everything I make or if I do any sculpting by hand.
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