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Giant Gourd Case? Answered

I like watching Naruto and one of probably everyone's favorite characters is Gaara. Gaara carries around a giant gourd on his back and I figured, why can't I? I thought about making a snowman out of beach balls as a mold and covering it with paper mache. Using that as a base I was wondering if anyone had any ideas on how to harden and waterproof the case. I thought about layering fiber glass or using plaster, but I'm not sure how heavy it would be. I also planned on making compartments, one on top for general storage and one on bottom with interchangeable parts like a speaker and a drink container with a tap. Eagerly open to suggestions. : )

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Wired_Mist

4 years ago

Well this sounds Potentially Awesome !

Traditionally you would use shredded fiberglass blown from a gun and skip the paper mache. If you do take the paper mache route keep the balls intact until the outer shell is cured to maintain the shape !

A more DIY Friendly alt would be with Fiberglass Mesh. You will need a few layers with each layer overlapping and turned 90* from the one under it. Basically the same method as paper mache.

For your storage compartments, use a Dremel tool with a cut off blade to cut the openings. If your new to the dremel and feel you may leave a noticable gap while you cut, you can take a 3rd ball and cut the doors slightly larger and sand them down to a Perfect Fit ! Just simple piano hinges held on with Epoxy should mout it nicely, or maybe twist to open?

**Safety note** Plz use a certified dust mask for cutting and sanding fiberglass !

Be sure to take some Pics; could make a cool First Instructable !

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Inari IXWired_Mist

Answer 4 years ago

Sorry it took so long to get back to this. I have a friend who's familiar with steel gauged wire. He often used to make chain mail rings. Do you think a frame made out of that would be a bit too heavy if I added it in?

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Wired_MistInari IX

Answer 4 years ago

Depends on the Gauge of the wire and how far the ribs are spaced. Only you can decide if it's too heavy.

Looking back, couldn't you use something like a boat float/bumper?

it's already the right shape and fairly rigid too ! just stiffen it up with a light gauge steel skeleton. You could also cut it with a knife or scissors that won't remove material like you would have to when cutting fiber glass. should help to eliminate any gaps around the compartments.

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Inari IXWired_Mist

Answer 4 years ago

That's great idea. I might try to build several different models if I can find inexpensive materials. I saw an instructable about recycling plastic bags into sheets so i want to see if i can make one out of that too.

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mpilchfamily

4 years ago

Use fiberglass cloth and epoxy rather than paper mache. Otherwise your good to go.