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jerodo8008
04-25-2010, 04:39 PM
ok, so I want to make an RX-78 cosplay, I've got some ideas on how to do it, but i'm not sure on what technique to use, fiberglassing, bodyfiller over foam, plywood, or even all sheetmetal... (shudders at the thought of the weight)

here's some reference pics:
http://lparchive.org/LetsPlay/MS%20Saga/Update%2011/42-rx-78-2.jpg
http://www.gearsonline.net/designers/rx-78-2.jpg
http://img46.imageshack.us/img46/3185/gds6446avq7.jpg
http://thecontaminated.com/wp-content/uploads/2009/07/gundam-rx78-3.jpg
http://thecontaminated.com/rx78-gundam-in-real-life/
http://otakusurf.files.wordpress.com/2007/08/a21rx78shootingbig.jpg

cash isn't a huge problem, i can allot $50 to $70 a week to this, so i'm not terribly worried about that, I'm just worried about my inexperience in working with most if not all of the previously mentioned materials.

any input is appreciated! Thanks ahead of time!!!

lynchingacers
04-25-2010, 05:16 PM
Sheet metal is doable IN A Shop but all the tools required make it not something the average garage can handle ( mostly shaping And Cutting Can BEcome The Problem)
and even with lightweight aluminum it still heavy
plus at some point it helps to weld it here and there and the thin aluminum is harder to weld than thicker Stuff at least for me
well that or pop rivets Which i personally Hate!!!!!

stick with fiberGlass or kevlar as carbon is like throwing money away with this kind of project
kevlar is supposed to have some crazy strength to weight when used with resin or epoxy but EXPENSIVE and a bit hard to work with just loo around online...
fiber glass over Green Foam for the Plug would be a start Then a light weight filler ( prolly like Rage or Evercoat Pastic Filler) and i stress the keep it THIN thin THin!!!!!

RAGE (http://www.summitracing.com/search/Department/Paints-Finishing/?keyword=Rage) kina costly but you get a whole galllon should go a long way if you keep the coats thin ( also thinner coats adds less weight)



as far as the costume aspect ive only made armor once out of steel 16GA
talk about time consuming!!!!!!!!!!!
mostly i make stuff out of aluminum Tanks Boxes ( 2 Coffin Lunch Boxes 100% hand fabbed and welded) other odd Small things

AS such Composite stuff is not something i know well Personally But i believe that can point You in the Right direction
but that body filler is real good stuff

Amaterasu
04-26-2010, 10:53 AM
Niiiice. RX-78-2 Gandamu. Very nice.


I'd suggest using foam board. Locally I can find sheets of foam at the hardware store and thinner sheets yet for crafts at the dollar store. Sealing it and then covering it in a thin layer of weave &/or fiberglassing (polyester) resin would make it very durable, lightweight and wearable as a result.

I wish that I could do and say more, but there are many experienced cosplayers on these boards who have done a mecha before. Unfortunately, I am not one of them.

saberslash
04-26-2010, 12:38 PM
http://www.cosplay.com/costume/58122/ by Featherweight might be a very good reference (detailed construction http://gundamgeek.tumblr.com/ ). He made it out of cardboard, hot glue, and comic book backers.

jerodo8008
04-26-2010, 06:16 PM
Wow, thanks guys, there's alot of very useful information there. I have never used pop rivets, but i've been tempted for a while to try them out. maybe to keep weight down use foam covered with something for big pieces like chest, back, etc. and metal for smaller pieces. cuz I've got a feeling that sheetmetal is spendy.

and my dad has a fully functional shop, we can do darn near anything mechanical in there, and we can do ALOT of metalworking stuff as well. he's got both a mig and stick welder.

thanks again! and keep the suggestions coming! You guys are awesome!

Snipes (aka Pocky)

lynchingacers
04-27-2010, 04:05 PM
if you do any sheet metal just be sure to give the edges a good finishing when youre done

i would suggest a De-Buring Knife as its really fast not too expensive and one of those tools you'll use every day possibly taking the burrs off everything in the shop( for some strange reason its addictive and fun...) ... that and a belt sander for finishing and shaping and such