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View Full Version : Ovan's Casket Arm worklog/Tutorial


DalaiLiam
04-21-2006, 05:38 AM
April 21

Ok, today I'm officially getting started. These are my refrences from the anime .hack//roots and the game .hack//g.u.

The Anime Ovan, alot simpiler. (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/ovandesign.jpg)
And the Video Game Ovan (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/ovanthumb.jpg) I have a much Larger wallpaper of the VG Ovan. For the most part, I will be working torwards the complexity of VG Ovan, But the Anime refrence helps since I can't find any VG refrences to the shoulder.

Ok, First off, I'm going to lit off what I plan to construct the majority of it out of:
Pink Insulation foam (super light)
Wood Glue
Poster board.

Largely so far the only tools I'll need are:
a ruler (and a long streight edge)
A foam Cutter
A fine point sharpie
double sided tape
box Cutter

I started off by drafting up what It would look like and then building a template in photoshop since I was too lazy to actually go look up CAD programs.(This means I'll have to measure these things out with a ruler when I print out the template)
What it would look like (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/ovanmath.jpg)
and a template (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/ovanarmtemplate.jpg)
Note this is just the bottom I figgure I'll start working on the barrel and work my way up. I also left options for unbeveled edges just in case they're too big for the foam cutter to cut.

The idea here is a piece of poster board sandwiched between two sheets of insulation foam. As this is already 13 cuts per pannel I decided to cut the estimated 16 faces I counted on the VG refrence down to 12... Still... at best... a full weekend of chopping.

Anyhow.. for now... I'm off to sleep as it's 6:30 and I woke up at 5 with a headache to start this. the pain killers are finally taking effect now, so Hopefully in an hour or two I''ll be running to pick up supplies, and then seeing how far I can get on this thing before work.

DalaiLiam
04-21-2006, 02:52 PM
Later that same day....

I hope the mods forgive me for not just editing it in, but significant bits have been added... that and if there's a text limit I'll probably meet it.

Work was canceled today, so I started testing this idea I had, I'm going to call it the "icecream Bar method".... because it looks like an Icecream bar. It seems like it would be a nice light weight way of making swords as well... or anything with beveled edges :P

Anywho getting started.... Yah big pictures I know.... I didn't feel like resizing, I just shifted the camera down to 1 megapixel(that's as low as it would go) sorry. Edit: Thankfully Photobucket resized them all. LOL

I guess I should start with my shopping list.
1/3 sheet of pink insulation foam(left over from other projects, managed to get 2/3rds of the thing out of it.)
1 wonder cutter. (Already had. Live by the foam cutter, die by the foam cutter)
1 packing tape (already had)
3x black posterboard(they didn't have white, only used 1.5 anyway) $1.80
1x Double sided tape $1.92
1x disposable box cutter with breakaway blade $1.54
1x Elmer's stainable woodglue $2.94

So just under 10 bucks so Far.

Anywho, I cut out the template I made earlier. Then used it to measure and cut (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0439.jpg) all the posterboard I would need. 12x center piece. and only one top, bottom, and side piece (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0440.jpg) since I could just pull them off and stick them on the next piece.

After all that was done It was time to cut the foam. I got out the old slide droor for my keyboard that I refused to use to use as a streight edge (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0432.jpg). In theory it should have been streight since the blade was flat against the board, but I guess the blade flexed a tiny bit. Not important. Anywho, I cut like this (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0433.jpg), and it went pretty quickly.

Next was to make some sandwiches. get some glue close to the edges (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0435.jpg), then well.. make a (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0436.jpg) sandwich. (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0437.jpg) Note that I kept a napkin around to wipe off any excess glue. You don't want blobs of glue on the edge because it takes time for the foam cutter to get through that. It's REALLY slow. Finally... Lay some stuff on it to Keep it flat (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0438.jpg). Otherwise it's going to want to curl a bit. When it dries though it will be rigid and streight and have next to no flex.

Now... Sit down wait for them to dry, and have some Ice Cream Sandwiches (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0434.jpg). The next part is really long and involved, so to keep you from being bored, here's a cat with a dirty sheet on it (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0427.jpg). EDIT: That really does say "COOK" as in kiss the cook.

Moving along... Remember all those little top, bottom, and side pieces you cut earlier? Now it's time to pull them out. I started with putting on the bottom. Make sure you use the pattern you cut out earlier, and line it up with the posterboard in the middle (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0442.jpg). The foam edges aren't always streight so if you just try to center the bottom, your angles will be off.

Now here is the magic of these two pices of posterboard. The foam cutter won't easily cut through them, so they act as guides. with the guides set you can just ride your foam cutter down them to get a nice accurate angle (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0443.jpg). This is why I think it would be incredible for making swords or beveled edged weapons.

Anywho, moving on to the top... I put on the side piece and the top piece, and just like the bottom, carved it out (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0444.jpg). The double sided tape I bought seemed to still be sticky, so I just peeled it off and stuck the side piece to the other side and cut away. (The tape actually lasted through all 4 pieces)

when I was done I pulled off all the pieces of posterboard I'd taped on, and the result was this: A 3-d copy of my template (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0446.jpg).

Now this is time consuming because the foam cutter moves SLOW. I should probably underscore that but I'm lazy. I finished the next four pieces in about an hour.

Afterwords I Grabbed all 4 and taped them together (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/HPIM0447.jpg) on the inside with some packing tape just to see how it would look untill I got them all cut and glued them together.

So that's where I'm at now. I'm out of insulation foam with 4 more pannels that need to be cut. Hopefully I'll manage to stop by and pick them up this weekend. Otherwise all that's left is some sanding(to knock those beveled edges on the top down to make it look round)

DalaiLiam
04-22-2006, 03:29 PM
April 22

Umm.. not much happened today, other than I finished off a total of 10 of the 12 pannels, taped them all together and realized how off it looked. The daimeter was waaaay too large as I had only used a ruler to guestimate. it was orrigionally 12" in diameter, but I would up only using 8 pannels, leaving me a nice large(but still slender) 9" barrel.

Here (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Picture005.jpg) I taped them all together on the inside, then I stood them up to make a perfect ring. Once I had it as close to perfectly round (3 of the 4 pannels measured exactly 9" to the one across from it. the 4th was 1/16th off) as I could get it. I taped down all the corners with packing tape (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Picture006.jpg) so that it would hold that shape.Then I flipped it over and did the same on the bottom. The result it was easily sturdy enough to lay on its side while I filled the cracks with woodglue. All the tape will be removed later.

DalaiLiam
04-24-2006, 08:09 AM
april 24

Yeah I had to wait on glue to dry most of the weekend, so not a whole lot of progress. I did however install a handle (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-24_003.jpg) and take a rather unflattering picture of myself (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-24_002.jpg) Displaying the bottom piece that was cut to cap it off. (still no fan put down there. yet, so it's not glued in, just fits snuggly.)

I should be picking up more foam later today(after work) and maybe getting all of the "Lock area" done tonight.

Jimmoman
04-24-2006, 10:11 AM
Nice choice of materials for the arm casket, I would've gone the same route. Keep up the good work on the tutorial, I look forward to seeing the finished peice.

DalaiLiam
04-25-2006, 08:06 AM
April 25

I was kind of slack ass last night... I went out ant ate Japanese with some firends and sat around and played PSO and Smash Bros.

Anywho.. this morning I did some quick things.
I added some reenforcement (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-25_002.jpg)s to the handle in the barrel.
And I started to address the colling issues this thing would have. (Oven is going to be referred to as OVEN from here out, on the basis that I'm going to have to wear 2 sweaters, pants, boots, and this darned insulation arm in a Georgia June and september.) I figgure the arm being in there casket will be the only part of me exposed to open air, so I might as well get some in there to cool me off. Fan (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-25_001.jpg). More fan (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-25_003.jpg). (That's at the bottom of the barrel BTW) The fan is blue LED lit for poohs and ha-has. It may add something, if not I'll just pull all the LEDs.

Today's project, the lock housing. Tomorrow (day off) Probably the first bell, maybe a bit into the seccond, and I think really hard about how I'm going to Get the ELwire into the lock houseing.

DalaiLiam
04-25-2006, 09:33 PM
... Meanwhile at the coscave!

Anyhow this is the update... once you take the plastic off both sides of insulation foam, it actually gets pretty plyable... I mannaged to bend it around a 10" radiaus without snapping it. :) A little heat(light heat, I was afraid to melt into it with the hairdryer on high and up close) and it was pretty much ready to lay down. this went WAY faster than I had orrigionally planned(since I was going to build it the same way as I did the bottom barrel with ALOT of sanding.)


Anywho... I got the fan working(I didn't have time to run to Radioshack to actually buy one of the plugs for the battery, so I just Soldered the wires dirrectly onto the 9v battery) Anywho, right now I'm doing time trials with the thing... It's been on and running now for about 4 hours and is still going strong. I'm just trying to gague how many batterys I'll have to bring to a con.

anyhow, here I am charinging the X-buster (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-25-later_002.jpg). LOL. Seeing this picture made me realize my handle was about 6" too low, and that I needed to move it up into the lock mechanism to drop the barrel to the right height. I also need to calk the insides of those cracks so that light doesn't escape.

Here's a clsoe up of the fan w/ flash (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-25-later_001.jpg) and w/o flash (http://img.photobucket.com/albums/v16/Dalai_liam/ovan/Ovan-4-25-later_003.jpg).

Kain666
07-10-2007, 11:20 AM
im currentley working on the casket arm too...but a bit differentley...check it out

http://images.cosplay.com/gallery.php?cat=81387&member=63381

good luck w/ urs