Remote/wristband 'communication devices'

A while back I posted up that I had designed a clip mount remote control fob holder for R5’s ‘Bad Motivator’.

The idea being that it could be glued/Velcro’d to the transmitters rear, allowing hand’s free’ish control of the remote.

Well with all the new 3D models I’ve been drawing up, one of them was a version of a communication wristband from Solo.

The purpose of this was purely as a costume prop, but I soon realised that it could actually be of use as a remote control wristband holder.

So I started changing design dimensions to suit the stripped down remotes internals and the first 3D printed version came out great!

(I just need to design a front cover/panel for the buttons)

This version, above, has had a few more alterations, like a retaining lip and also a location for a Brass insert to be fitted to secure the front panel.

Next was to modify this second design version to suit the other remotes. This version I also drew up the cover/panel at the same time as the wristband.

And here it is......version 1....

The two holes on raised pads are for screws to secure the front panel on, via brass inserts.

I did some more alterations to accommodate the four button remote control I have. This version required the cover/panel to be more raised as this remote has raised, tactile switches, compared to the low profile, metal contacts of the above version circuit board. To combine the fitting of the cover/panel, the main wrist holder, now has a 'lip' for the panel to slid under. This helps secure the front better and requires only 1 screw.

The above picture shows them pre retaining lip and retaining screws.

The four button remote has been the hardest to get right. I've gone through more test prints on this version than any of the others.

I've also increased the 'shell' thickness to hopefully increase the strength of the wrist strap slots.

The 3D printing with increased shell thickness and a new curved strap slot, have made them stronger.

I’ve posted up a short video on my YouTube channel. Click the picture below to view link:

I’ve ordered some Velcro (as I couldn’t find my stash), this will be for the straps.

Throw Back Thursday - Han Solo costume for Celebration Europe 2016

This week’s throwback is to the Han Solo costume I made for my Son, to attend Star Wars Celebration Europe back in 2016.

Originally he wanted to go as a Stormtrooper, but I persuaded him it wouldn’t be very practical or that it would last to be worn again. After I showed him a pic of Han after they escape from the trash compactor scene & him wearing a Stormtrooper's belt, he was sold.

The boots were off eBay second hand, but in perfect condition & the trousers were bought from Tesco’s. The shirt, jacket (vest) & scaled blaster, were made by myself with help from Karen.

Here are some of the links to the making of his outfit:

• The beginning
• Never tell me the odds
• E-11 scaled blaster build begins
• The vest work begins
• Boots
• Trousers

Hope these help if your thinking of making something for yourself or your kids.

Jessika 'Testor' Pava - 2019 Update...

Well.....it's been a while and should really get back onto this project. My daughter did re-try on the jumpsuit last year sometime & yep, you guessed it, she'd grown in height. I obviously wasn't thinking ahead and had cut off the extra length in the legs as thought to use this material for pockets etc. So am going to have to start over on this by buying a new one.

The chest box I made out of cardboard, this was great fun to make. You can check out the start of this project here.

I have since then been asked by her if we could make a few other outfits so I need to source info on these and see if these are viable, easier/simplier/longer lasting lol

Jessika 'Testor' Pava - helmet - 2.5

Work done 19.6.2017

The inner 'ear' area, needed to be raised up to form a central pad area. so I glued in some cardboard to build this up and then applied filler to slope the edges.

To create the rear helmet details, I used Milliputty.

These are rough to start with.......

More updates on this project coming as need to redo some of the costume for my daughter.

Jessika 'Testor' Pava - helmet - 2.4

work done: 15.6.2017

Next up I started on re-doing the 'blast shield'. I'd already attempted this once, but wasn't happy with it, so decided to try again a different way. This is all new to me so I soon realised I had to think back words.... by this I mean that I make the shield, then make a cast of the shield, to then make it into a mold, just like the helmet.

Started off by making the shape using cardboard.

A few more layers of cardboard to make more rigid,

before applying fiber glass matt and resin.

Here is the first layer of fiber glass matt applied.

I added another layer on top of this to help strengthan.

Once this was dried I started to mix up and apply car body filler.

I ran out so this was all that was left in the tin.

pic....

Whilst waiting, I started looking at the details that I could add to the helmet to be included in the actual casting of it. Rather than have to stick extra pieces on.

I started on the cheek detail (circled in yellow below)

Other's have done these, so there was plenty of ref pics to work with.

And this was the mocked up version...in cardboard.

And here it is glued into place

I still need to fill in the gaps etc and then seal it before applying primer etc.

But it's looking good, and after all, this is for my daughter so scale is not 100%

Jessika 'Testor' Pava - Flight suit 2.2

Work done last year 13.6.2017.....Thought these following post's had been posted


Usual busy family weekend stuff, but i was able to re-make a start on the blast shield. Using a hot glue gun to get started, i cut out and positioned roughly where the sides would go. Next was over the top strips, cross strips, followed by larger flatter pieces.

The start of the cardboard strip framework.

Next then was to start applying fiber glass and resin to form the base of the shield.

Resin applied to framework.

The plan is to create the shield, then make a silicone mold to then create a slush cast from it.

Jessika 'Testor' Pava - helmet - 2.3

With my daughters timely reminders that I've not done any work on her costume lol, I got back on to working on her helmet.

I've been reading but mostly watching since I started this project, You Tube videos of how to cast helmets and this multi-part tutorial has been invaluable source of info for a first timer, budget build attempt at casting a helmet.

Click on the picture to take you to his You Tube Channel

He stopped posting due to work commitments but as his viewing numbers show, he has been useful to others.

~~~~~~~~~~~~~

Here's the start of me applying cardboard around the edges.

I've also ordered some clay, and next will be to buy silicone tubes.

Am looking forward to this with each little step lol.

Jessika 'Testor' Pava - small update

Had to put this on hold, but not for much longer lol, daughters nagging me :D

Have got some elasticated material for the flight suit cuffs. It's just a case of fitting everything in, time wise.

Then once more free time is available, I'll make my first attempt at molding.....her X-wing helmet. Still work to be done before I get to this stage tho.

Jessika 'Testor' Pava - Flight suit 2.1

2017 and after Xmas/New Year am feeling positive about things.

With a free afternoon on Sunday, I got out my daughters flight suit and accessories and got to working on it again. I started by remeasuring her in the suit, yep, still fits lol. I then measured marked and cut off the excess sleeve & leg material. These bits I can reuse as pockets etc on the suit.

I left enough for hemming the edges and also the arms will need elasticated cuff material. There's also plenty of space and length to last her a few years growth lol.

I then led it all out for a mock-up picture.

There were a few bit's I'd misplaced for the straps, but for now, this is work so far.

Jessika 'Testor' Pava - helmet - 2.0

Helmet gets the chop!
25.11.2016

I really wasn't happy with the size. I know, I know this should of been sorted at the start, but I had hope things would work out.....

So after some thought, I marked out some cut lines and then used a saw blade and my Dremel cutter, to cut off the cheek/ear sections.

As my daughter was tucked up in bed asleep, I had to wait till the next evening to measure her head and test fit the separate pieces on her. I just hope this plan works and can salvage what I've made so far!

So the next evening, I dug out some foam and with some help from her brother, we managed to better fit the helmet cheek sections to the size of her head. I then measured the remaining gaps, height & width's to be able to cut & eventually, fibre-glass all the parts back together like a jigsaw.

Well, here's the start...

Measurements at the ready.

Additional cut lines for the dome section.

And then test fitting of the sides and the new cut down front dome section.

 Front view

Rear view

Feeling a lot more positive about how this 'rebuild' is going. This is ALL guess work regarding cut lines etc, tho so far so good lol.

Jessika 'Testor' Pava - helmet - 1.9

Two steps forward, one step back :(

Thought I was getting somewhere, but had a few set backs on the build.

Found another weak point on the helmet. So had to chip off the filler and remove the paper. Then found there wasn't any fibreglass behind! One thing with using yellow paper is that it's not easy to see the difference.

So this needs fibre-glassing and then re-filling.

Next was the blast shield

Well, what a mess! The sides didn't take the right shape of the helmet, the main curve section moved when the fibreglass was setting and the recessed channel section didn't fit the helmet. This became more noticeable when test fitting.

Didn't take any photos as was to disappointed

So I cut off the side flats. Trimmed down the upper curved section as was too large and the recess channel more noticeable as a mis-alignment with the helmets. When lining this up the shield is lopsided. Am going to try to recover this...... But not happy with the wasted time, money & materials :(

But was STILL not happy.....hence no pictures.

Decided to carry on with working on the raised ear area crescent, as can just be seen in the above picture. Below, I made up some cardboard walls. I covered the cardboard with masking tape as this stops the filler sticking to it and leaves a smooth finish.

 Hole filled in as well on rear of helmet

Taking shape. Some sanding, shaping and then more filler in the gaps.

I also filled in some other areas.

 This rear area needed to be raised up to by symmetrical

More disappointing updates to come.....

Jessika 'Testor' Pava - helmet - 1.8 - Blast shield

17.11.16
The printed off template I had used for the blast shield, I wasn't 100% happy with. The shape didn't seem to match that of the helmet dome. I know this version was designed for use with matt, not cardboard tho. The sides are larger than they should be, just to add strength to the paper for when applying the fibre-glass matting.

I cut down the 'step' as looking at reference pics, it was to 'high'. Basically I just cut the distance in half.

I plan to fibre-glass the ends first to then be able to fix the blast shield in place on the helmet. This will, I hope, help with being able to then apply fibre-glass matting to the blast shield to get the correct shape.

Got both ends glassed up and also the leading edge to help keep the shape.

Helmet & blast shield test fitting

Which gave the shield enough strength to be placed on the helmet to test it.

As you can see the helmet has received some marking up. This is to guide me later with filler, shape & also to dremel to create ridges etc.

More work hopefully over the weekend.....

Jessika 'Testor' Pava - Flight suit & Chest Box 1.6

16.11.16
Started on painting up the chest control box.

Used some sample cardboard and applied paint to see how best to apply. Used a brush which didn't do so good. So my daughter suggested the sponges :). Applied a few layers to build up the coverage of white, allowing it to dry between coats, without it soaking in to much and warping the card. I didn't use any special paints, just kids stuff.

Once dry, I mixed up some white & black to get a dark grey. This I then painted into the grooves.

I then dry brushed over the edges etc to get the worn look. Next up was mixing some white & blue to get a light blue for the two buttons.

18.11.16
I've almost finished the painting now. Mixed up some white and black to paint the grey switch's.

X-wing TFA chest box, 95% painted

just one more button to be painted

Just need to paint the central button silver.