Bondo Mud!

I've seen this technique used before on other forums so I thought id give it a go.
You mix car body filler (bondo) with polyester resin. Most bondo is made using polyester resin so they're compatible, but always check yours first. Once mixed you use the normal red catalyst paste you get with the bondo. The mixture is like mud, and easier to spread than bondo alone although it is more tacky of the surface.

Jonathan

First filler down

First layer of bondo is on and lightly sanded. Starting to look nice and rounder.

Jonathan

Reenforcement done

So I went ahead and started applying the Polyurethane reenforcement and found two layers are more than enough. Each layer was 200ml when mixed so it's combined to 400ml. Starting to feel like a real shield now.
Hopefully I'll get some time to work on it tomorrow.

Jonathan

From Jonathan's Projects

I had a bit of time yesterday so I decided to apply some Polyester resin to the outside of the shield. This is to serve two purposes,
1 - To help stiffen it before applying the Polyurethane to the inside to help stop warping.
2 - To help fill any small holes there could be around the joints.

I plan on applying the Polyurethane on the inside tonight, probably looking at about 3 coats minimum, but we'll see how we go.


Jonathan

New Project

From Jonathan's Projects

So the Iron Man armor has been a no go since the last post. I haven't had the drive to continue it.

But last weekend I started a new project, the Hylian Shield from The Legend of Zelda: Twilight Princess. I came across the Pepakura for it more than a year a go but never made a start till now. The Pep comes in two parts, the main body of the shield and the detail which is then attached to the top.
I've completed assembling the Pep, but I've not attached the detailing yet. I plan on waiting until the shield face has been filled and rounded until I add the detail otherwise it will just get lost under the filler used to round the face.

I've also added a brace to the back to keep it rigid until the fiberglassing has been done. I hope to start the fiberglassing this weekend.

I downloaded the Pepakura file from the Section Sixteen forum. The links below, however you need to be registered to download the attachments. As they're not my files I'm not going to link to them directly, you will have to register to get them.
http://sectionsixteen.freeforums.org

Jonathan