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Hi. Have finally got around to making another instructable!

This instructable is being entered in the Hurricane Lasers Contest.
Im currently trying to revamp the art dept at the school where I work and part of that I getting a laser cutter. I want to show the students how to design things for the machine and hopefully inspire and inform them of possible options their futures could take in the world of art and design. I also want the students to design and produce things that they can sell for the school to generate more income for the dept.
Right now im currently working on various ways to raise 50k to do up the dept and winning a laser cutter would be a ginormous help to bring the art dept up to date.

This is how I made EVE from the film Wall-e. It was one of my final pieces for Uni. I studied Modelmaking for Design and Media. Its courses like this I really want to inform and hopefully inspire the kids at school to look into.

(You may also see in the photos another little sculpting project going on - it will be another instructable!)

Step 1: Working Out the Sizes

To get the sizing right for Eve I looked into how she was designed. There wasnt a lot of info I could find about the size so I used scale referencing. Using the scene where she holds a rubiks cube and a light bulb I could work out her height.

Step 2: Forming the Body and Head

After getting the sizes I needed to work out how I was going to make her.

I decided that a fiberglass shell would be both strong and light and would give me the finish I needed.

So now I had to work out how to make the shape I was going to make the fiberglass mold over.
Initially I was advised that lathing wood would make a good form, but it would weigh a tonne! So then I thought that plaster would be easily shaped and smoothed and I can bulk out the majority of it with polystyrene.

Quick trip to B+Q for some large sheets of polystyrene and onto the hot wire in the workshop to cut out the contours for the body and head. (the square ones are the head pieces before being trimmed to circles)

Step 3: Formers for Forming the Body and Head :)

Now I had the polystyrene cut to size I had to create a way of shaping the plaster over the blocks that would leave them evenly covered.
To do this I used to Uni laser cutter to cut out profile shapes from acrylic.
For the body it was a circular base that could have a pole through the middle and a curved acrylic shaper that would spin around the pole.
The head was similar but the head was on a 'spit roast' like design and the acrylic scraper was static. This had to be done because the head was a totally round piece where the body could have a flat section as it was going to be shaped anyway.

Step 4: Cover the Body in Plaster

Now for the fun bit.

I mixed a bowl of plaster and started slapping it on! When needed I spun the scraper around the body to make sure the plaster was creating the right shape. I did it in stages so the plaster had time to settle and to clean off the former regularly otherwise the plaster would gather underneath the spinning bit and this would move it to the wrong position.

Step 5: ....and Now for the Head

Same as with the body. Slap on the plaster, leave to set so it doesnt fall off and slap on more, spin to shape and clean up as you go!

Step 6: Sand and Shape

Once the plaster was all set I could remove the pieces from the formers, shape and smooth them.

Step 7: Seal the Deal

Once the shaping was done I had to seal the plaster using Shellac. This was so when putting on the fiberglass it wouldnt react with any water in the plaster.
After a few coats of Shellac the forms were then polished.

Now they are ready for the fiberglass.

Step 8: Fiberglass the Body

Made the fiberglass in three sections so they would be easily removed from then former.

At the end of it all I now had the mold for Eves body!

Step 9: Fiberglass the Head

A slightly harder task. I had to make sure the join did not go over where her face was going to be cut out as I needed to use the shape to vacuum form the screen for her face.

Step 10: Back to the Body

Now the mold was ready, it was polished (with about 3 or 4 layers of fine wax) so it would release the final cast.

Layering up fiberglass in the mold was tricky but I used a fine fiber mesh to make it easier. Using a white colour in the gel coat was good to use in case the paint that would be put on got scratched at all.

Once out of the mold the body could be cleaned up and any rough bits sanded and smoothed.

I then cut out where the arms would be going.

(as you can see my cat thought I was making a home for her!)

Step 11: Arms

Using the sections of the body mold I could form some fiberglass for the arms.

So they would be light I used these shapes as a former for on the vacuum form machine.

Step 12: Heads Up!

To cast the head was tricky.

First I fiberglassed the top section. When this was dry I cut the face hole out. I could then sit this piece into the bottom section of the mold and fiberglass the underside of the head.
Then another round of smoothing and sanding :)

Step 13: Face Screen

For her screen I made a fiber glass former using the original mold and vac formed super clear styrene.

For the eyes I laser cut loads of sticky dots (couldnt find already done ones the right size) and put them where her eyes were to go on the inside of the face screen. Then I sprayed the back with black and then a translucent blue.

Step 14: Last Few Bits Together

For the arm sections in the body I used vac formed pieces (same as used on actual arms) and fitted them in with car body filler. The body was then lined with foil (this would reflect the light better once fitted)

Am access panel was cut into her back for fitting the neck etc.

For the neck once again is vac formed super clear styrene and frosted on the back. I laser cut stickers and stuck on a ring of angled squares that would be the neck glow. This was then attached in with car body filler.

In the head I used small pieces of styrene around the edges so that the face screen could be sat in but removable and lined with foil after spraying.

Everything was then primed with white primer and sprayed with several light layers of cellulose paint. To create the shine I didnt use lacquer as it can put a yellow tint on white things. I had put on several layers of paint so I could use 'micromesh', a super fine polishing sandpaper, to polish the whole head and body to a mirror shine (this took ages! but worth it).

The stickers were peeled off the neck.
Clear acrylic rods were fitted through the body to hold the head and arms.

A steel bar was fitted through the back so Eve could be attached to the wall to look like she was hovering.

Finally I put LED lights in her (Xmas lights for the body and a couple of small lantern torches in the head). The Xmas lights were great as they could be set to a pulse glow that was perfect for her.

Step 15: FInished EVE!!!!

All finished and on display :)

Hope you liked this instructable!
<p>NO FAIR!!!!</p>
<p>NO FAIR!!!!</p>
Thats some great work, and clean finish! congratz
Congrats on being a runner up in the contest! Just wanted to let you know that this project has totally inspired me to try and pursue my own after college graduation next semester!
Awesome!
awesome i like this.
you should make the arm come off by <br>using magnets, so you can literally put your hand <br>threw the arm.
really amazing work!!! very professionaly.....Excellent....you are an inspiration for all the comunity.....thnx
Amazing quality of workmanship. I wish i had a teacher like you when i was at school. What an inspiration!
Thankyou. I wish I had one too! I didnt even know what modelmaking was actually about until i went for the uni interview! <br>I hope to inspire even just one person into discovering this sort of thing early :D
wish i could buy a mold from you
I wish I could get a mold from u
This is awesome! I absolutely love your documentation (I'm going to make some MAJOR revisions on my 1:1 M-O based on this- thanks!) and I am truly in love with your PIXAR art!<br /> <br /> Have you ever heard of a group called the <a href="http://movies.groups.yahoo.com/group/wallebuilders/">WALL-E Builders</a>?&nbsp; They're doing something similar to this, except with 1:1 robotic WALL-Es.&nbsp; If you're ever interested in adding electronics, servos or possibly a dot matrix display inside her to make her more robotic, these guys are fantastic
ooo will have to look into that :) <br> <br>glad this has been a help to you! :D when starting this project i was originally going to do M-O hes def my fave character!
M-O is awesome and adorable. I've got a basic shell for his head, body and arms made from Wonderflex, trying to get all the electronics working on him so he'll be able to go and clean my room for me.
beautiful = ur creation <br>best = ur creation <br> <br> <br> <br> <br> <br> <br> <br>
:D
Incredible!
thankyou :)
<font size="5">O M G!</font>
:D
Beautiful work, excellent instructable.
thanks! :D
well why did you feel its right to vent your frustration on my instructable? why dont you winge at the site for that? <br>ive been using this site for a long time and think its good even when people just show what theyve made. its great to see how creative people are being. <br> <br>ive made this instructable to enter a comp for the school where i work so having people (well youre the only one) picking at it is really annoying (to put it nicely).
This is really cool! I'm always impressed with the level of artistry in the world, and I very much enjoy when people share their processes. As I've never worked with fiberglass, resin, etc., a lot of this leaves big holes in my understanding of what's going on, but I can always look up all that other stuff on here or on the Web, right? <br><br>Anyway, it's obviously really great work. Good luck in the competition!
Very awesome indead!
Hi, <br> <br>An amazing realization, contragulations !!
you could use magnets to hover the head over the body and if you place them right they would keep the head perfectly positioned. same for the arms. Just a thought..
Magnets were suggested to me at Uni too. But to find ones that would work and balance it all out? No time and on a students budget! <br>And the arms really wouldnt have worked that way :D
Making the arms float would be MUCH fiddlier, but the head is easy (excuse the shitty ascii graphics) (poles as seen from above): <br>in the body/neck: <br> n <br> s <br>n n <br> <br>in the head: <br>s s <br> s <br> s <br>You would get three stable positions 120&deg; apart, and would have to weight the head so it's balanced with the electronics you put in and floats at the right height.
I said this to another person on this string and as I was saying it I was wondering how hard it would be to modify the insides to do it. &lt; That is a good idea. I used to have a toy like that on my desk. Problem is that if you wanted to modify the design - For example turning her into a real robot or a Computer tower you are back to her having the rods again. &gt; I think she would make a Great computer tower. Just need a few hidden doors on the back for the wires.
That is a good idea. I used to have a to like that on my desk. Problem is that if you wanted to modify the design - For example turning her into a real robot or a Computer tower you are back to her having the rods again.
For the head you could use neodymium magnets. With the same poles facing, so that they repel each other. With three or more sets equally spaced around the neck there will be points where the head will settle, at the points equidistant between the magnets, where the magnetic field sags. You could have the body magnets on a rotating disk, radio controlled, which would then let you turn the head remotely. Put some motion sensors in the room, let a computer triangulate and work out where someone is and the head could follow you as you move around the room. Spooky.
sparten11 nothing personal but how would you balance tre arms with magnets ? just wondering because I couldn't think of a way in which that's possible :D
i would imagine EVE could be &quot;framed&quot; by at least 3 magnetic walls reacting with carefully-placed magnets placed in her arms, head &amp; body keeping her fairbly stable... <br> <br>i don't even want to think about how time-consuming that would be...
*fairly
Ive seen quite a few instructables that i wouldnt have a clue how to do the things they say and some people dont do a step by step they just show what theyve made in one pic. <br>This one is a 'how i did it' and funnily enough its instructable enough that the moderators accept it and its been featured on the front page. <br>Its not hard to fiberglass something, the technique is easily googled or found on you tube. Or there might be a 'how to fiberglass' instructable on here. This is how you could make an EVE not how to fiberglass project.
So, all I need is a full on fiberglass workshop? <br> <br>It's really good work!!! I wish I had a place to do these things :-( <br>Truly amazing craftsmanship!!
Thanks! <br>This was done at uni where i had access to a special room for it. Anyone can do it really. Ive done fiberglass commission work in my garage! All you have to do is order the materials :) <br>(just make sure the place you use can be well ventilated, i just leave all windows and doors open and wore a filter mask)
odd how the forms take on the look of marble at this stage. i suppose if someone wanted faux marble columns or some other structure, this would be a good way to obtain them.
It would be a good way. with the shellac though you only get the brown colour. maybe there is something else around that would leave a grey colour with the shine :) <br> <br>The forms were sat outside the modelmaking dept for ages and looked great for a while (also very useful for propping the door open he he)
I used to be a professional modelmaker, making stuff for films, exhibitions and museums. You pretty much did things how I used to. Glad to see the techniques have not died out. It's very labour-intensive and modelmaking to time and time and budget constraints often takes the fun out of it. Well done.
Thanks! <br>It is a labour intensive job - mainly sanding lol. Most techniques dont change much as why change what works? :D <br>yeah costing kinda reduces some things but it can make it a challenge and its great when you find something you can substitute for cheaper :)
Very impressive work! I have a suggestion for the 'forming the body' stage. You can sculpt the parts in rigid foam to finished or near finished form. The pink or blue variety used for insulation has a very fine grain to it. If you have access to a air sprayer, coat the sculpt in a VERY watered down solution of drywall joint compound. You will end up with a quasi plastered model suitable for molding. The prop shop I worked at years ago used this for prototypes to be ultimately cast in plaster and fabricated in fiberglass. Keep up the good work and good luck!
Thanks. This project is about 3 years old now and I was a little limited with materials, student budget etc. but thanks for the suggestion, its another thing for me to look into in the future! :D

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Bio: Hi! A little about me! I graduated BA Hons Modelmaking for Design and Media in 2009 and am now an art technician at a school ... More »
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