TUTORIAL Neck Brace pattern

[Gypsyboy]

Ok, check out the first post in this thread. I have edited my post so it now includes the template for the neckbrace backing.

Hope it's helpful. Keep in mind, this is based on measurements taken from OT helmet reveal necks, and it may or may not be suitable for other versions of the helmet. If you're using a Rubies or some other version of the helmet you will have to consider this and possibly make mods on the template to make it work for you.

GB

[darkblade]

great start for me GB, thanks!

[GLADUS63]

I've finished my 8 molds of the split plug I have, these take the shape on only on side (because it's hard to get rid of the air bubbles), I make this week a first casting and I think they are (not perfect) good.
I used an epoxy resin that become hard with 1/0.5 rate of catalyser, and soft with 1/1 rate, so the visible side is hard and I cover the back with flexible resin when it's still not cured, and it's like the original on the visible side, I will post pics tomorrow !
In these operation I killed 2 silicon molds !!!
the resin is very agressive with the silicon mold

Cedric

[GLADUS63]

Here it is, taken with a cellphone camera
http://www.sithtrainingtemple.com/sithgallery/displayimage.php?pos=-286
You can't see on the pic that some little bits doesn't exist in some casting because of the air bubbles which stay in some little holes !

[firebladejedi]

Very nice looking good job! Im thinking of starting a reveal project soon as my costume is starting to head down the ROTJ route.

[GLADUS63]

I finally compared my splitplug to the small horizontal flat holes on the neckbrace, and it result this :

width of each holes : 5 mm = 0.197"
height of each holes : 0.6 mm = 0.024"

space beetween to holes : 3.25 mm = 0.128"
height beetween 2 lines of holes : 1.6 mm = 0.063"



Cedric

[Gypsyboy]

I have updated my first post with a pic of the textured leather I am using for the neckbrace until such time as I can get something more accurate. I'll be updating as the project continues.

[darkblade]

just printed and scaled up your drawing GB, at first I thought it looked kinda small, but after flipping it, transferring it and building it, it is a nice fit, can't wait to get home and start figuring on attaching it to my helm!!!
again, nice job GB!!....

[Gypsyboy]

just printed and scaled up your drawing GB, at first I thought it looked kinda small, but after flipping it, transferring it and building it, it is a nice fit, can't wait to get home and start figuring on attaching it to my helm!!!
again, nice job GB!!....

Yup. Even I think the half neckbrace image looks small. In fact, even the full size one seems small until you actually put it on the neck of the mask. suddenly - when you consider the extra width the padded rolls will add - it all makes sense.

[darkblade]

Was anxious to see it built, made a very basic one from stuff found around the shop, after transferring the pattern on some tin flashing, I covered it a large piece of heat shrink, then added some edgeing, after looking again I saw the edging was quite a bit bigger and padded looking in the photos, having nothing else on hand I stripped the jacket of a piece of 2/0 (aught) cable (around 3/4" diameter) split it down the middle and pressed that on. actually not looking too bad, will post a photo tonight or this weekend. and it all took me about literlly 10 minutes...LOL course there are no bits on it or texture

[darkblade]

here is my ten minute (start) to a neck brace using GB's pattern

[Gypsyboy]

Nice job. The tubing over the edges works really well. Pad up the top one to be a tad thicker and you'll be all set. The only thing is that the pattern I made was just the flat surface of the perforated metal, so overlapping the tube on the edges of that will make it smaller. I should have mentioned that.

[darkblade]

hmmm, ok maybe I'll try stripping some 4/0(aught) cable that is arond 3/4 to 1" in diameter for the top. the heatshrink tubing I used for the surface gives a nice flat(texture) not quite rubber but not quite leather, the main body is tin flashing. now that I am home will look around here, I just need the tidbits to glue on now!!
how are those split plug molds going?

[Gypsyboy]

The heat shrink looks great. And I think the 1" diameter cable should work great for the top.

Great work.

[kalkamel]

Here's my scratch built neck brace:





When building it at first I used Darth Micah's tutorial (http://www.tk7524.com. Click on "costumes" and then "neck brace") but then i decided i want to make it look at least similar to what's in the movies. What I used as a base was a rubber mat with adhesive backing, the type you'd find on the steps of a bus , hence the horizontal lines. I cut out pieces of the same mat for the raised parts and added a rubber hose for the top and bottom part of the brace. Then I screwed on some studs and glued on some snap button parts, added a electric cable connector for the middle part and voila! Its connected to my lid with velcro. So far, it does a good job of covering my neck!