Step 3: From Polygons to Smooth Curved Surfaces

Once you've built up enough layers of fiberglass to make your pieces nice and strong, the next thing you need to do is smooth out the faceted surface of the pieces so they'll stop looking like low-poly computer models and start looking like heavy pieces of armor. 

Here's what you'll need:

A grinder with a sanding flapwheel
Automotive body filler (commonly known by the brand-name "Bondo" and available at your local hardware store)
A smooth surface and putty knife to mix your Bondo
A flexible plastic spreader (probably for sale on the shelf right next to the Bondo)
80-grit sandpaper
100-grit sandpaper
150-grit sandpaper
Eye, ear, nose, and throat protection so you don't fill your delicate parts with nasty, nasty glassfibers.

Use the grinder to take down the corners on the paper model.  An 80-grit flapwheel will make quick work of the fiberglass and paper, but it will also make a huge mess of nasty, toxic dust.  It's best to work in an outdoor area and you'll still want to wear eye, hearing, and respiratory protection.

Once you've knocked down the high parts, you'll want to build up the low, flat spots with some Bondo.  Use a flexible spatula to spread the material out over the surface and build up a smooth curved surface.

When working with Bondo, make sure that you only mix up as much as you can use in about ten or fifteen minutes.  After that it'll turn solid and you'll end up wasting a lot of material.    If you add too much, you can always sand or grind it off after it hardens.  If you add too little, you can simply add more after it hardens as well.

Once you're satisfied with the smooth surface you've created, it's a good idea to spray on a coat of primer to get a uniform color to get a better impression of how smooth the actual surface really is.  Chances are you'll discover that you're not as done as you thought you were and you'll want to add more Bondo and do more sanding.

You'll repeat all these repetitive steps repeatedly for all of the individual armor components.  It's going to make a mess wherever you're working as well as quite a ways downwind.  Consider this when choosing your workspace.

If you're like me, you never make one of anything.  To make these forms into the basis of an army, proceed to the next step.

If you're a rational, sane person, you can skip ahead to step 8 and use the smoothed, reinforced paper models as one wearable costume. 
<p>............ My............... mind............ Broke........</p>
Not only would a Camelback be a good idea to wear under this suit, but you could effectively install some small CPU fans along inconspicuous parts of the armor and use the backpack as the power source to provide ventilation. It was something I was considering for an Ork Meganob build. It'll also give the suit a living humming sound which could only help.
<p>That is a bloody brilliant idea!!!!!</p>
<p>Nice work. Someone needs to take that, make it out of metal (or some kind of super-durable plastic) and add &quot;muscles&quot; like this one: <a href="https://www.instructables.com/id/How-to-make-air-muscles%21/" rel="nofollow"> https://www.instructables.com/id/How-to-make-air-m...</a> </p><p>THAT would be a step towards REAL power armor. Anyone think they have a chance? (No way I could, but someone could :)</p>
<p>I just attended the Minneapolis Wizard World Comic Con, and my armor was a hit. Too heavy and unwieldy, but I'm happy with the way it came out overall. Thanks to Thorssil for the inspiration and instructables, they were a big help. This one was fiberglass and Bondo, but I'm already planning on knocking together a vacuum forming machine and redoing it in plastic.</p>
<p>No way! I live in SLP and I am currently making one but i was nowhere close to finishing it in time for the Con. I still have a question though. Could you post some pics or something on how you strapped the pieces together? especially the shoulders. </p>
<p>Here's the shoulder mount that I came up with. The should pad slips down onto the ball and the brace holds it in the proper position. The arm hangs from a strap that attaches to the top of the shoulder.</p>
<p>Awesome! did you 3d print the ball or buy it some where else</p>
<p>heheh...the ball is a 2&quot; wooden ball from Michaels.</p>
<p>Also how many layers os fiber glass did you put on?</p>
<p>I used 3-4 layers of fiberglass.</p>
<p>You should post an Instructables on how you made it!</p>
Here is a question. If i make the skeleton first for the parts that dont move then chicken wire and then fiberglass that would that work or will there be something wrong with it?
I know you must be terribly busy, but I'd actually like to know if you'd do other things from the 40K universe. Im actually looking for a Tempestus Scion cosplay and I don't have the materials or skill to do it myself.
<p>how much does it weigh</p>
<p>Just finished my first full armour build so thought Id let you guys see it. My thanks to Thorssil for his excellent instructable which helped to make the build a success.</p>
<p>Oh my god, your first picture is <em><strong>priceless.</strong></em> The idea of a seven foot tall armoured space marine from millenia in the future coming to Earth and pointing a deadly weapon at a little old lady doing her shopping on a foggy winter day... :'D</p>
<p>That particular picture appeared in the Sun newspaper with the tag line &quot;I paid for the carrier bag honest mister!&quot; but yeah the thought of a local supermarket hiring Space Marines to enforce the new carrier tax is somewhat amusing. She was just a random passer by and was genuinely terrified of it, the little kid however wasn't phased in the slightest n just had to figure out how he could play with it. lol</p>
<p>can you link me to the artical?</p>
<p>Who can I pay to build this for me?<br>Seriously, I want to have it commissioned, but can't find a proper store.</p><p>Anyone have any ideas?</p>
I'm available for commission. Shot me a message and I'll see what I can do for you.
<p>Hey, I'd love to commission a suit of unpainted armor from you. Please reach out if you're still interested in taking any commissions at this time!</p>
How much i have to pay to get one of those armours in my size?? and with shipping to germany?
<p>Since other people are asking, could I commission you for an iron hands with a powerfist? (Maybe a vanguard or assult marine?)</p>
How much for a lifesize blood raven terminator armor and are these wearable?
<p>i'll build it for you, but she wont be cheap if you want it real soon.</p>
<p>lazy mother trucker</p>
<p>sometime .. u dont have access to the technology and tools :D</p>
It's incredible builds like this that make Instructables the best place on the Net for DIY inspiration !
<p>Hey, are you taking orders for one of there by chance?</p>
<p>OH MY GOD thats freaking amazing!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!</p>
<p>So, my topic question is: What holds the pieces together? I know in the video you mentioned straps. I assume they go from piece to piece or do they run a full length? For example, the legs. Do you have a strap that goes from thigh to knee cap, then another from kneecap to shin, or just one piece going from thigh to shin and tied in the knee on the way? What kind of strap? Buttoned? Velcro? Riveted? I assume more than one as well to keep them from twisting, possibly one front, one back, and one on each side? And the rubber filler pieces, were they glued on as well?</p><p>Hoping for this to be my next project. Been waiting til I had enough experience and confidence to go extreme (to this or close to this degree). After using stilts for my 8 foot tall Frankenstein in the mall, I can say I am comfortable on stilts around kids and people. Just the patience to build it...</p>
<p>Fantastic job! remember playing with the minitures as a youngster, only thing i didn&acute;t like was the colour...But as an old long fang these days that&acute;s to be expected ;)</p>
<p>Truly epic, you used the most common or cheap materials to build something awesome. <br><br>Congrats the size is killer and I bet many people will buy it for sure. <br>BTW I&acute;m not even a warhammer fan.</p>
<p>that picture of you with just the torso on is hilarious! Thanks for the laugh</p>
now build a chaos version... and a Dreadnought
<p>Hey Shawn, Myself Ankit I'm from India, I just love your work man, you are truly awesome. I always follow your blog and all your stories and work helped me to build this giant..Its 7 ft tall, i know somethings are missing but i won Comic Con India with that cosplay and that was my &quot;Embrace Yourself&quot; pose.Hope you like it..</p>
Wow! Great craftsmanship.<br>Not many people will hit the &quot;I made it&quot; button.<br>Congrats.
<p>One thing that I thought about as far as the hydration goes. Have you considered a hydration backpack, such as a camelback? Also, you appear to have some extra space in there, you could build in some ventilation fans that would help with cooling.</p>
<p>Hey, someone that gets atmoshperic pressure and a distributed load!</p>
<p>Cyanoacrylate = Crazy Glue/Superglue.</p>
<p>Dude...awesome...simply awesome!</p>
<p>showing this to my friend who wants to go to a con as one of these guys next year.</p>
<p>showing this to my friend who wants to go to a con as one of these guys next year.</p>
<p>showing this to my friend who wants to go to a con as one of these guys next year.</p>
<p>showing this to my friend who wants to go to a con as one of these guys next year.</p>
<p>showing this to my friend who wants to go to a con as one of these guys next year.</p>
I was about to start on the project when I realized that Pepakura wasnt Mac compatible. Does anyone know of a good Mac program thats similar to Pepakura?
<p>Don't know if this is still needed but you can actually use the Pepakura Viewer on a Mac using Wineskin. Look here: https://www.youtube.com/watch?v=4cfqLrklu50</p>
hey was wondering if you would be able to make me a suit of grey knights armour I'll pay you handsomely oh and then ship it to Scotland again I'll pay you please message back with rough estimates cheers

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Bio: I'm a wayward sailor lost in the midst of all manner of tinkering. When I was a kid I learned that the way to ... More »
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