bishopdonmiguel Posted September 28, 2021 Author Posted September 28, 2021 (edited) Gaffi, part 3. I picked up 2-feet of 1” round aluminum tube to mount a mace head. As the diameter of the tube is only slightly smaller than the gaffi handle, I decided to mount the tube using a slug because I’m concerned with the wood sidewall splitting should any angular force be applied. When the slug is connected to the gaffi with a long screw, it should transfer most of the force applied to the tube down the wood handle. I purchased 3” of round rod that fit inside the 1” tube. I drilled a hole through the diameter of the screw thread then then drilled a countersink shaft the size of the screw head about 2” deep. This allows the screw to sit inside the slug and provides enough thread to create a strong attachment to the gaffi stick. To provide additional support, I applied some 2-part epoxy when installing the slug. I wanted to create a grip guard for additional visual interest so I glued 2 pieces of scrap whitewood and cut a hole 1” through to accommodate the tubing. Drawing a circle and roughly cutting with a chop saw provided a wheel shape which I then shaped with my belt sander. I hollowed out the edge so this piece would slightly pass over the gaffi to provide a finished look once installed. After applying some texture, this is ready for some stain and polyurethane. Once I get the mace head designed, I will decide how long to cut the tubing. I’m guessing about 16”. Edited September 28, 2021 by bishopdonmiguel Quote
bishopdonmiguel Posted October 8, 2021 Author Posted October 8, 2021 Gaffi, part 4. I want to add a leather grip and strap. Thought I’d decorate the ends with some brass rings. Got a set of 5 cheap. Definitely not solid brass but that’s fine, I don’t want a shiny finish. Sanded the finish off to reveal a white metal underneath which is more pleasing to my eye. The strap I cut from scrap left over from the belt boxes. Folded it over, cut a 1” hole and then dyed. I installed this with a bit of E6000 then used one of the rings to lock it in place. The grip is more scrap leather. I embossed a textured pattern for some visual interest. After dyeing, I affixed the grip to the rod using contact cement. Another ring at the top finishes the grip. Quote
bishopdonmiguel Posted October 8, 2021 Author Posted October 8, 2021 Gaffi, part 5. To finish this gaffi, I designed and 3D printed a mace head and collar. I painted these to suggest something like an iron alloy. The shiny aluminum rod seemed out of place so I etched it using a chemical I had on had. Gives it a blackened, aged look. I will use 2 of the remaining rings for additional visual interest. I also blackened these with the same chemical treatment. Before affixing the mace head, I drilled a small hole. This will break the pocket of air in the tube so the head will not bounce around while the epoxy sets. After affixing all the pieces, the gaffi is finished. Quote
bishopdonmiguel Posted October 9, 2021 Author Posted October 9, 2021 Neck scarf. This is the last piece of the costume. It will help keep the extended next from the mask in place and prevent any skin/balaclava from showing. The velcro will be hidden once wrapped. Next up, approval pics. Quote
bishopdonmiguel Posted October 9, 2021 Author Posted October 9, 2021 Took some approval pics. Didn’t have anyone help with a face shot so I can’t submit until I get around to doing that. Any issues that I should correct? Quote
bishopdonmiguel Posted October 13, 2021 Author Posted October 13, 2021 Photos submitted for approval. A little photoshop fun while I wait to hear back… Quote
Nezhdanov Posted October 13, 2021 Posted October 13, 2021 Well done on getting to the end of the project! I’m sure the clearance process will be fine, I don’t think there’s anything that would be a problem. Hope you have fun at future troops in this costume [emoji1303]Sent from my iPhone using Tapatalk 1 Quote
bishopdonmiguel Posted October 23, 2021 Author Posted October 23, 2021 To commemorate my approval in both the 501st and Rebel Legion, I decided to decorate the Craftsmen rolling case I purchased for transporting the costume. After painting & weathering the case, I cut stencils from metallic vinyl, spray painted and weathered the decorations. Sample of my process below… Quote
Nezhdanov Posted October 24, 2021 Posted October 24, 2021 Congratulations on the clearance [emoji1303] hope you have fun out there!Sent from my iPod touch using Tapatalk Quote
bishopdonmiguel Posted January 15, 2022 Author Posted January 15, 2022 A good friend made and gifted me a "Mini Me" TK action figure when I received my 501st approval. Using the same process, I wanted to make one for my Tusken. First I had to acquire a cheap, vintage Kenner Tusken. This little guy was well used... I spend some time repainting with stuff I had here on hand. Leather is darker than my Tusken but I'm fine with that because the Kenner figures were never perfect representations of the characters. Some weather and a vinyl cape I purchased from eBay, and this guy is done... Now to make some accessories. 3D modeled a gaffi in the same style as mine and printed... I felt the gaffi needed to be a little thicker, especially at the bottom. Instead of adjusting the model and reprinting until it was right, I opted to add some Milliput. That gave me better control over the process and I could finish the surface easier than working directly with the PLA. For some silliness, I created a small bag of "desert sand." It's just the kind of useless accessory that action figures sometimes have... A little label for the sand and some paint for the gaffi and this Tusken is ready for a card... For the character card, I used one of my approval photos and a picture I took in the Dakota Badlands a few years ago. Printed on adhesive photo paper with my inkjet. The little green rectangle is what the figure will stand on... Mounted the prints on a piece of comic book cardboard... Before finalizing the card, I needed to print and apply a vintage price tag... Lastly, ordered a blister from Empire Blisters and encased my "Mini Me" Elder Bishop in clear carbonite for eternity, or at least until the glue gets old and fails... I will get this boxed up in an acrylic case and my TK will have a companion. Quote
fleasome Posted January 15, 2022 Posted January 15, 2022 Small typo on the card. It should read Ages 54 and up. That is so awesome. 1 Quote
Nezhdanov Posted January 16, 2022 Posted January 16, 2022 Enjoyed the trip down memory lane and it’s pretty cool to have sort of your own retro action figure! Good attention to detail [emoji1303]Sent from my iPhone using Tapatalk Quote
bishopdonmiguel Posted May 1, 2022 Author Posted May 1, 2022 I spent a few weekend days working with my granddaughter on her Jawa costume. Was great fun and we got to troop together for a couple hours at Planet Comicon. One of the things I really enjoy about Star Wars costuming is how it brings people together, both family and friends. 2 Quote
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