Something I should have done in the very beginning -
MAKE A TAPE DUMMY!
Fitting, modifying and adjusting the suit needs to be done accurately and doing it on my own body is darned near impossible.
With a tape dummy to my exact proportions, I can build and modify the whole suit on it and have it all fit together exactly, being sure that it will fit me when done.
I watched some U-tube tutorials by a guy called STEALTH on how to make this.
First a supporting frame has to be made out of PVC pipe. Then it's just a matter of putting on some thin clothes that you don't mind cutting up, tape up the sleeves, ankles and waist then get an assistant to wrap you up like a mummy in PVC Duct tape.
I couldn't believe how good it made my back feel... I might have to tape up my back every day before a start swinging the chainsaw at work!
Once covered from ankle to neck, then it's a matter of the assistant cutting the silver suit off - just enough to wriggle out of it, which can be slow and tedious, but taking your time is key.
Next insert the skeleton support and start to tape up the cuts, leaving the torso open until last. Stuff the whole suit with newspaper, rags, sheets, foam or whatever you have and pack it right out. The tape won't stretch beyond how it was while you were wearing it, so your form is retained.
I've run out of tape (used three rolls of 30 metres) so I'll have to pick up another roll tomorrow and stuff the suit as soon as possible.
This is going down as one of the top few weirdest things I've done.....
Just fell off my chair ................ are you sure this is the weirdest thing you've ever done Baz ?????
B&D ................................... ...................... If I had known you wanted to do this I could have loaned you a wetsuit and a couple of old bean bags for fill or my Drysuit which can sealed and inflated!
Just fell off my chair ................ are you sure this is the weirdest thing you've ever done Baz ?????
B&D ................................... ...................... If I had known you wanted to do this I could have loaned you a wetsuit and a couple of old bean bags for fill or my Drysuit which can sealed and inflated!
No no.. I said, "One of the wierdest...."
You'd never get your wetsuit back mate. It's going to get covered in paint, fibreglass and all sorts....
You are a talented man Barry - from a perfect observatory to this time consuming marathon effort! You wife must be either VERY tolerant/patient, or prefers you out of the house
You are a talented man Barry - from a perfect observatory to this time consuming marathon effort! You wife must be either VERY tolerant/patient, or prefers you out of the house
On the grounds I may incriminate myself...... no comment on the wife's behalf....
Left thigh assembled. This one was a little more difficult than I expected. For such a large piece it is made of an incredible amount of small parts. Very fiddly cutting and folding on this one.
This is the first part I've made that came with braces to go inside it for shaping. This way I can harden it then cut the braces out and it will retain the correct shape.
I tried it on my leg and it fits perfectly, even allowing for thick and loose tracksuit pants, later to be replaced by bicycle long-johns and the padding inside the armour.
Checking for fit. By the time I get the inside fibreglassed and padded, then the undersuit - there won't be much room left in there. Should be a snug fit.
I spent a few hours immersed in toxic organic fumes today in the shed, while sleet and snow outside kept the resin temperatures low.
I painted the inside and outside of thigh and shin with resin, then bit at a time - poured in the slush-cast.
One thing I would do in future, is tape the knee joint together before doing anything. I was lucky that the slush-cast was still a bit pliable so I could bend and squeeze the knee together then tape them in place while it sets properly. Before I line the inside with fibreglass matt, I will do the same again.
