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My current project, the Alphonse Elric suit of armor from the anime Full Metal Alchemist. I have no particular interest in making armor but I thought it would be a great way to pratice my metal shaping. I also learnt to make chainmail so I could fill some of the gaps, in between the arms, legs armpits etc. it won't be wearable, more of a static display. Once finished it will stand at about 2 metres tall.
I started out with a plastic model of Alphonse, using it to make patterns for all the parts I would have to make. I merely used masking tape to replicate each face of the parts. Then I scanned them in and scaled them up, tracing them in solidoworks to make the patterns. I then had them printed out 1:1 scale on A1 paper. It was then a simple matter of cutting out and sticking them on to the alu sheet and cutting them out.
If anyone wants the patterns you can get em here
http://www.fmamotorcycles.com/index.php/alphonse-a/
Note though: Some of the simpler parts I did not make patterns for. There is about 25-30mm of excess on some of the pattern edges but not others. Hopefully I'll have it finished by the end of the year, time permitting.
I started out with a plastic model of Alphonse, using it to make patterns for all the parts I would have to make. I merely used masking tape to replicate each face of the parts. Then I scanned them in and scaled them up, tracing them in solidoworks to make the patterns. I then had them printed out 1:1 scale on A1 paper. It was then a simple matter of cutting out and sticking them on to the alu sheet and cutting them out.
If anyone wants the patterns you can get em here
http://www.fmamotorcycles.com/index.php/alphonse-a/
Note though: Some of the simpler parts I did not make patterns for. There is about 25-30mm of excess on some of the pattern edges but not others. Hopefully I'll have it finished by the end of the year, time permitting.
pdfs.rar1 MB
Please post a full Step By Step when finished! Instructables could use more Anime related projects.
Can't wait to get it finished but I am sans workshop at the moment. (in a city apartment atm, sucks!)
As soon as I get some space I was going to get back into.
Enjoy!
Yeah I'm building a new website. I'll attach the PDF to this permanently when I get home from work.
The account at fmamotorcycles is suspended... :-(
If possible, it'd be great to get a copy of the pattern uploaded and attached to the 'ible. Or just uploaded into someone's account, and linked here in the comments?
I don't think numbering will help you, like I said in the description these patterns were made for metal shaping. You can't just cut them out and expect them to fit all together, they weren't designed like that sorry.
You'll just have to play around a bit. That photos of all the patterns laid out would be a good start, that how they go together basically.
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When I started looking in to welding aluminum years ago lot of people were saying it was really hard to do blah blah. It isn't really that hard, maybe a little trickier than steel but not much. It basically come down to practice. It only probably took me a few hours of practice to get pretty good beads down with a TIG welder but once you have the hang of it and you practice your beads will get better.
I use both a TIG ( Tungsten Inert Gas) welder and an oxy/acetlyene setup too.
Both units are pretty standard in metal fabrication. The only thing
that really changes between say steel and aluminium is the shielding gas and
the mode of current. Aluminium is welded use AC ( Alternating Current) while steel uses DC ( direct current)
So basically as long as your welder is an AC welder or a switchable AC/DC welder and you have the appropriate shielding gas (Argon) you can weld most aluminium. Most people welding steel will tend to use a Argon/Co2 mix or other combination which don't work well for TIG welding.
You can MIG weld aluminium too but the results aren't quite as neat as TIG welding, well atleast for thin guage materials anyway. As long as you have the correct wire and Argon.
The oxy/acetlyene is a bit like TIG except you use a bottle of oxygen and a bottle of acetlyene to generate a naked flame to melt the metal to be welded.
It's alot harder than any of the other welding procedures I use but it comes with the advantage of the weld being pretty much just as soft as the bits of metal welded together. This makes it easier to hammer out the weld making it near invisible between sheets. Oxy/Actlyene is very useful for that reason when shaping sheet metal. Both TIG and MIG leave brittle welds so when you
hammer them out they'll crack usually.
There is alot to go into but thats about the basics. if you have any other question drop me a message.
I think for wath I had in plan this type of welding is too hard and inaccurate.
Because of the precise mechanish.
Anyway thx for the quick answer and tips ;)