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meanlilkitty — Sgt Calhoun Progress
Published: 2013-04-03 21:26:45 +0000 UTC; Views: 2842; Favourites: 35; Downloads: 28
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Made from stone clay, this is the base that I then cast out of brush on urethane rubber. Just finishing casting the back piece--can't wait to get to painting! I hope to debut her either at Fanime 2013 or AX 2013Related content
Comments: 23
I was wondering if you still have the Calhoun references? I am also trying to find as many back/side pics as possible! Rubber is a great idea, btw. I was planning on molding and casting the front in two separate pieces so I could vacuform it, but casting it in rubber would be best all around! Your sculpt looks AWESOME, btw! Do you have a life cast or are you doing it on a mannequin?
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Sure, just email me at Ashley@thepropsshop.com and I'll share them with you. I've actually finished molding and casting the costume, but I ended up not liking the urethane rubber I used. It was temperamental and wouldn't dry in places, and did NOT want to stay painted. So I've moved on and trying Flex Foam. It's been easier to mix, it's more flexible, and overall lighter. I've yet to see how painting goes, but I'm very hopeful. Basically the original is made from stone clay on a mannequin that is roughly the same size as me. The other benefit is that after I finished molding and getting the clay off the mannequin, the outlines from the clay were left over, so I could make sure my seams matched up
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uhm....can i have the references too?? 
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email me at ashley@thepropsshop.com and I can send them to you
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I am impressed, never thought of this possibility. A friend of mine was interested in doing this cosplay but we couldn't figure out a way to do the chest piece. Was even wondering if there is a pepakura file out there but couldn't find one. Kudis to you for this sculpt!
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Thanks much! Haha have the mold, now just trying to get to the finishing part XD
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Yay, sounds promising. I am sure this will be a great costume and a success at any convention!
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love it! i am currently making a calhoun EVA foam armour, and it is soo hard finding the right angles to see how to make a pattern. i finished the front chest piece and the back piece pattern, but trying to find a picture from the back from the movie is almost impossible. i have never worked with clay or molds and kudos to you!
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Yea, I"ve never really worked with clay either, but I can't stand doing those kind of measurements haha
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Urethane rubber, then that mold shall have resin poured into it right?
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No, the rubber urethane is the final piece. The mold is made with silicone rubber and plasti-paste and I used brushable urethane to make the final armor. Now for the very long painting process...O_O
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Mate, mind if I ask ye about a project idea I have to make MotherMolds for hollow helmets without Smooth-On products. It's a stupid idea, but I believe it CAN be done.
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I don't have a lot of experience, only started making molds last year, but I'll help out however I can
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[link]
The mold builder that she uses ( [link] ), if fiberglass were added into the process, AND would be used at a larger scale, could a mothermold for hollow helmets that capture the mold details, be made?
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You can always give it a try, but I've actually used that mold maker before, and it doesn't terribly work. I put about eight layers on a AC crest and it was never solid enough to support itself. What you're thinking could possibly work, if you do a few layers of the latex and then layers of latex and fiberglass. The problem may come up when you're trying to demold it, the mold needs to be flexible enough for you to get the piece out without you breaking it
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Oh man this is so amazing! I was toying with the idea of doing Calhoun for a while, too, and the chest piece is really what was holding me back.
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Oh well I'd be happy to share references if you'd like. Calhoun almost never gives us her back or side in the movie, so it can get a bit difficult. Haha I actually found additional pictures of a Calhoun doll (it's ugly but has most of the details) and someone took all the little pieces and took individual pics of it all. It all has to be supplemented with the movie references, but it's a start. Her outfit really is a rip from Gears of War and Mass Effect, and one of my friends did a female shepherd using techniques like this, so I used it as a base. Basically just using stone clay to make the model, made a silicone rubber mold, used plasti-paste to make the mother mold, then used brush-on urethane rubber for the final piece.
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Oooooooooooo! I'm so excited to see the costume when it's completed. I was planning on doing a Cahlhoun cosplay eventually! Perhaps you can give me a few tips at fanime 2013?
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Haha sure! You'll prolly find me in AA hawking my wares
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Awesome! Can't wait to see the final product! Good luck with the rest of it.~
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