Legolas (Almost Ready)!

Ooooh! So close, but still not done! As I mentioned earlier, I realized once I started gluing the parts of Legolas together, that I had completely mis-sculpted the angle of the bow-hand and ruined the mold. The part fit at an odd angle and the string and arrow just didn't look right. I am not sure why that happened, as I was very careful as I worked. But, nevertheless, it happened.

So... I glued and painted all that I could, then using the glued Legolas as a reference, I resculpted the bow-hand. As it happens (and to my good fortune), the casting resin weapons (in this case the bow) comes back out of the mold rubber in one piece because it is hard and sturdy. So, all I had to do was remove the ruined clay hand and clean the bow, then re-sculpt the hand only to match the completed model.

To date, I have finished the re-sculpt and have re-molded and re-cast the parts. I need only apply the paint and glue, string the bows, then mount the models on the stained and finished bases. I'll post completed photos and bid listings in a later post.

Till then, here's the model thus far... Notice my mini-production in the last image. Both my Gimli(s) and Legolas(s). Or is it Legolai?

Legolas From the Mold

And I had just about enough money left on my project budget to mold the Legolas parts.

Since the models are screw mounted down to the rough wood bases that I sculpted them on, the feet come all the way through to the top of the mold (remember that the models are poured upside down). That gives me two giant pour holes to send the resin down into the mold. I, of course, prepared this mold like I did the Gimli mold (2 posts down) by adding chase tubes to get air out of trouble spots. See the "stick" or tail that forms on the Legolas body (3rd image) to ensure that resin flows up into the ends of his tunic. These extra bits and the flash (mold seams), are removed and sanded to clean the part up before painting.

Notice again that I created 2 Legolas's (like the Gimli) so that I would have one for me and one to sell. My finished and painted Gimli makes an appearance in the last image.

Gimli Painted and Ready!

Alright! It is truly a wonderful feeling, that after putting so much love and work into something, it turns out better than you were expecting!

You can see from the images the unpainted model, with the arms glued on, and the axe kept separate during the painting to make getting the brush in and around his arms a little easier. I sanded and stained the wood base myself.

And then, the completed kit looking very cool and awesome. And, did I forget to mention... I have a mold and can make more than one of them? As of this post, I have 2 Gimli(s). I am keeping one (of course) and will be posting a bid on eBay (hopefully as early as this weekend) for the other one. See the final VR spin (at the top of the page) for a complete look at this custom model and keep a lookout on this blog when I list the first one up for bid.

(More to come)...

Gimli From the Mold

Well I finally found the time (after 2 years of work) to buy some mold material and resin and start the final phase of my project.

After assessing any areas that might trap air in the mold (when I poured in the resin), I added chutes to the model to create air "chase holes" in the mold. Since the model would be poured upside down in the mold, areas of concern for me were the draping chainmail (which would be pointing up and catch an air bubbles). Air bubbles mean that those pieces would not get any resin into them during the pouring, and thus not form right.

Satisfied that I was ready, I built a cardboard container around the body and parts and poured in my liquid rubber. The rubber I'm using is a more "amateur" friendly version, but good enough to do what I needed.

Mold rubber is a two-part mixture of latex/silicone and an activator compound. Which, when mixed with a spoon or stir-stick, gets a lot of tiny air bubbles in the rubber which threaten to degrade the quality of your mold as you will get pockets all over your part. A professional grade rubber requires a vacuum chamber (into which you place the mixed rubber container) to pull the air out of the rubber before you pour it. The stuff I am using is less costly and doesn't require the vacuum. It is a lesser quality rubber (won't last as long), but is designed to greatly reduce the chance of bubbles settling against the part. Thus, I get a good mold, with less cost and equipment, but I won't be able to make as many parts from it.

Also, the reason I had to be so careful about getting a good mold the first time around is that you inevitably destroy the original part when you are removing it from the mold (see last photo). One shot, baby and months of work are destroyed. But luckily, I can now replicate Gimli in resin and I see that the mold is good! If I notice any irregularities, or pieces not forming because of a bubble, I can jump right into that area of the mold with an exacto knife and carve a chase-hole myself and usually straighten out the next casting.

I am now ready to make my final Gimli (s)!

Aragorn (Not Done, Yet!)

As I mentioned in the earlier post (below), I have actually been sculpting and working on Aragorn for the longest of all of the models. This one has been plagued with problems since I began it right after finishing Gimli.

The first sword that I carved out of the resin snapped on me and I could not successfully glue it back together straight enough to work. So... I had to re-sculpt it.

I went through nearly 6 head sculpts on this model (at the start of the project) and had trouble capturing a like-ness that I was satisfied with. Although I finally got it and am happy.

I got nearly all the way finished with the body sculpt and realized that somewhere at the very beginning, I had gotten my proportions off and he came out with small legs and large head/torso and he looked ridiculous standing next to Boromir and the others. So... I salvaged his upper torso and head (by breaking them off of the model), and re-sculpted him all the way back to re-doing the armature. Once I had a new properly proportioned armature, I re-connected the upper torso to it and added the new clay to start his legs and jacket again.

So... Here I am with Aragorn still not completely finished, but heading in the right direction (finally). The image below shows that his tunic, jacket and arms are not yet finished, but should give you an idea of what his pose is like. Stay tuned for details about his progress and the completed model.

I plan to get back to completing him after I run up a few more molds of the others. I have had some of them finished and sitting around for nearly a year and a half, and would just like to see them finished before something happens to them!

Aragorn stands at 12" inches tall.

Boromir, Blow your Horn!

No, I haven't forgotten about Aragorn. I have been working on his sculpt off and on this whole time. Since I had finished Legolas and began work on Gimli. But that is a story for the next post (above).

For now, feast your eyes on Boromir "Man of the West" and Son of Denethor!

Sporting a sword, sheath and his famous horn (a separate piece at his feet in the photo), Boromir is complete down to the embossed leather bracers and the fine fabric weave on his tunic sleeves and collar.

As the 8th model finished, Boromir stands 11 1/2" inches tall (he's sort of crouching).

Took Long Enough

The last of the hobbits I sculpted was Peregrin (Pippin) Took. As I mentioned in the earlier post (just below this one) Pippin was sculpted at the same time as Merry as they were positioned to work together.

Pippin had one crazy distinctive weave on that shirt of his, but as crazy as I am, I captured its texture into my sculpt. Notice the knit weave on his scarf, as well!

Pippin stands 8 1/2" inches.

All is Merry and Bright!

Are we still keeping track? At model number six, I present... Meriadoc (Merry) Brandybuck!

A very prim and proper hobbit, he can be seen sporting a very intricately embroidered vest, cloak and sword. He stands at ready and was sculpted together (near simultaneously) with Pippin (see above post) so that their poses actually work together as they are posed to protect each other.

Merry stands 8 1/2" inches tall.

Frodo Lives!

Frodo is modeled clutching at the ring and staring off under its spell! He has sting held by his side and will be completed with an actual aluminum chain and brass (gold-ish looking) ring link at scale with him (see the bag of shiny stuff behind the model!).

Also, just because I was insane and on a roll with the project, I went wicked crazy on the details and engravings on Sting (see photo). Using a large jeweler's magnifying light (and lots of patience), I scratched the elvish runes along the blade from a very large close-up I had of the movie prop.

Frodo stands very erect at 8 1/2" inches tall. Sting is 4" inches long and is molded with hand on the hilt.

What in the Sam Hill?

My fourth sculpt (and first of the hobbits) was Samwise Gamgee. I started with Sam because I was still working out my ideas for Frodo, yet I wanted to at least get a "Hobbit" scale model to compare to the others for size.

Sam comes with backpack, water skin, pots, pans, etc. He is fighting ready with his sword and skillet! See the earlier concept sketch post for a full idea of the pose.

I am looking to start molding and casting Sam in the next batch of models I take to completion.

Sam stands at 8" inches tall.

Dwarfing all Others

The 3rd model that I sculpted was Gimli. I had a lot of fun being very meticulous about all of the fine engravings and details all over his leather and armor.

My only problem was that for a long time, I had difficulties getting the boots right and that the armature inside the sculpy clay was loose. This meant that I spent a LOT of time on the boots. If they weren't breaking because of the model wiggling on the base, I was re-sculpting them because the details were not close enough to the film version.

The boots in this early photo are not the final ones, and in fact, his feet on this early version were too small in proportion to the body. See the coming post of the finished model for the final boots.

Gimli was the first model I took all of the way to finish and will have ready to sell. He stands 10" inches tall to his head (12"inches overall due to his raised axe not seen in these images).