Imperius: Shoulder Guards

Ahhh Imperius, you wide bastard. These bad boys were fun to make, and where my first foray into making an actual silicone mold. Without further ado!


Using the models I ripped from D3, I made a properly sized template out of pep for the base, and after transferring it to plastic and a lot of heat shaping (of which there are no pictures), I made these!

DCIM0320 (Medium) DCIM0318 (Medium)

God these were ugly and unwieldy, and cleaning them up was a nightmare because of the low res of the model and the thickness of the PVC (3mm). I decided to focus all my energy on making one shoulder to mold instead of all 4 big chunks.

IMG_0361 (Medium)

I started by patterning out the detailing on each side, and cutting it out of 2mm PVC. This was a mostly trial and error process involving a lot of cursing and measuring.

 IMG_20130305_180817 (Medium)IMG_20130305_180833 (Medium)

After this, I added the outer trim detailing, and built up the top using Apoxie Sculpt. Lots of sanding here, as usual. LEARN TO LOVE THE SANDING.

CIMG0675 (Medium) CIMG0674 (Medium)

To finish it off, I used another piece of 3mm PVC and sanded it into the curvy beveled shape in the cross bit. For some reason I do not have pictures of this hand sanding process, but it was all done with the random orbit sander. After this, it was finish sanding and.. mold making!


Sloppy first run, this whole thing ended up being garbage and I had to redo it. Valuable lessoned learned, namely take your time, and FILL ALL YOUR SEAMS. After another try, my one peice mold was complete.. and it was time to start casting. Because I am still poor, this was a 1 part mold when it likely should have been something else. I had to slush cast it of sorts, and each cast took about 40 minutes to make.. but in the end..




Using the cool ideas of Henrik Pilerude, I made ball joint mounts for the shoulders to set into, a quick and dirty collar section for the shoulders, mounted it all together and wala. I also made the 3rd inner piece out of the base frome earlier and some pvc/apoxie sculpt for the detailing, then made vac pulls of it to use for both sides. I dont have many pictures from this period as it is around the time I got promoted and the hours started taking their toll on me, sorry. I will probably expand on the shoulder mounts later.


Behold, this nerd! Next up, the Bracers!


Imperius: Breastplate (continued!)

Hey all, I’m not dead, just lazy! I haven’t been keeping this page current with my progress, shame on me! Time to start the long process of fixing that. Here is part 2 of the breastplate boogaloo.

Imperius has a thing for the Sun, it seems. . I wasn’t sure how exactly to build this, so I just started from the lowest level and went to work! I roughed out the shape below after a bit of trial and error, and cut the first layer out of 2mm PVC.

CIMG0624 (Medium) (2)

And two more layers, designed by bullshit and guesswork.

CIMG0628 (Medium)

from this point, I glued these pieces together, then filled every gap with Apoxie sculpt to create the bevels and sanded it for ages. After much pondering on how to get this thing I have created to curve so splendidly, I made my choice and cut this thing I had just completed right in half.

CIMG0629 (Medium)

After more filling, sanding, and cursing, the finished cleaned up master was ready for my dumb idea!

CIMG0633 (Medium) CIMG0642 (Medium)

I made Vacuform pulls of both halves of the chest piece, and cut out the Vac formed halves.

CIMG0648 (Medium)

Perfecto! Oh wait, nevermind, you cant bend a hollow object without horrifying warping. I scrapped that idea for another one, and filled both halves of the vac pull with that same cheap fiberglass resin I used for the Spears sun. I didnt get any photos of this process as I pulled the resin out of the “molds” before it had fully cured, and quickly bent the 90% cured resin to shape with a heat gun and my hands, then screwed it into place and worked on the next. After it finished curing on the chestplate, I was able to photograph my dark work.

 CIMG0657 (Medium) CIMG0653 (Medium)

Turned out better then it should have, honestly. Also at some point I removed the collars (they are removable), and added detail trim to all 3 of them. After a bunch of cleanup and filling and finish work, it was time for the primer and sanding phase.

CIMG0666 (Medium) CIMG0663 (Medium)

Primed, sanded, bolted down, reinforced in the back with apoxie sculpt (to fill the space between the chest and the resin)

CIMG0670 (Medium) CIMG0671 (Medium) IMG_0344 (Medium)

Filled, sanded, and done! The detailing was a mixed bag of scrapbook flourishes and plastic. Things you can find at Michaels. I am still figuring out what process I want to use (and paint type, weathering etc) for the paint job, so it will stay grey for awhile longer. There will be many more addon pieces for this, backplates and abs etc, plus a mount on the back for the wing mounts. Still, the big work is done!

Stay tuned for the Shoulders!

Solarion : Spear of Valor (Diablo 3)

In preparation for my upcoming Archangel Imperius build, I am making the spear he uses throughout Diablo 3.

This is what I was trying to build.

This is the goal

This is what I actually built.

(For higher resolution and more images of finished build check the gallery to the right!)

Below is a rough outline of the steps I took to create this spear!

Using my scaled ingame model as a reference, I made some templates and cut the basic shape of the main blades out of 3/4ths inch thick Expanded PVC (Sintra). Found a scrap of the stuff big enough to host the blades for $8, score.

The next step was to take this and get sanding. After marking a line down the center of the plastic where I wanted the edge to be and blocking off the areas where the edge stopped (I used painters tape as a physical barrier ontop of the lines you see.. this is extremely helpful in stopping accidental deviations) I began my dark and prolonged work with the belt sander and orbital.

These blades are a little over 2′ long. This spear will be large.

A little crooked, but not bad for a first pass.

Edge takes shape, this process took about 40 minutes per blade. Thankfully I only had to do this step once. This plastic was harder then I expected.. perhaps it was not sintra after all.

First pass complete! Looking pretty smooth.

Drew up a template for the inner blades and started working on the circular plate the sun shape sits on. I ended up making a vac pull of a small food plate I found and cutting the plastic version to the size I wanted.

Using photoshop, I drew up a pattern for the star shape that sits ontop of either side of the blade. That thing is going to be a pain to make.

Before tackling the star, I traced and cut out 4 of these from 1/4th inch expanded PVC (Sintra), this is the first finished one after sanding it to shape. Since these sit flush against the blade in the cinematic, the blades only needed to have an edge on the top side, I did almost all of this work with a handhend random orbit sander (best tool ever). The blade is about 4″ long.

I like where this is going very much.

I decided my initial idea of building a support frame with styrene and filling in with apoxie sculpt somehow seemed like too much work, so instead I thought I would try something new. I cut the star out of 1/4th inch Sintra and got to work.

Using a combination of a dremel and orbital, I sanded down the edges of the star into fine points. This was not very easy, and I made a lot of mistakes on the inner sections.. I filled these with Apoxie Sculpt and sanded that down by hand, and it turned out as good as I was hoping. This alone took a little over an hour and a half of sanding.

I cut out the center circle, and made some teeth for the inner circle out of the same 1/4th Sintra and sanded them down to shape using mostly a belt sander and curse words. How I held onto those little .5″ long diamonds and sanded them to shape I may never understand.

Since I have yet to cast anything or use silicone molds.. ever.. and I was NOT going to make a second one of those stars, I decided to try something a little different with what I did have available to me.

Using 1mm Styrene sheets at high heat I made a pull of both masters. The thin styrene and high heat made the inside of the pulls grab a huge amount of detail. I cut the shapes out of the sheet and filled them with cheap fiberglass resin from home depot (the $26 a gallon stuff.. terrible)
Maybe one day I’ll be able to afford smooth-on.

Even I was a little surprised at how well it worked. Two perfect sets of resin casts, this is where the fun starts.

After some cleanup and a few coats of wetsanded plastic primer.. they are looking pretty smooth indeed.

I found a cheap ($5) 6′ long vinyl coated pine closet rod at Dixiline that will work perfectly for the spearshafts base. I cut a channel for the shaft in the base of the blades, and after lining it all up.. glued it in place with hot glue like a pleb. I then added two long carriage bolts going from either side into the shaft for added stability.

All of the sanding required to make the circular shaft flush with the blades (1.25″ width shaft sanded down to .75″ width) made that spot fairly weak.. so I fixed that with a pair of thin steel plates on either side of the blade going down the shaft. This thing isnt going ANYWHERE.

I added the rays of light and a border to the main blade sections, and started mapping out how to attach all this together.

After a lot of primer and finish sanding, I finally was able to assemble the head and take a look.

Going to work on the spears shaft now. Will update soon.