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Old 24th June 2017, 2:41 PM   #1
ASIGN_Baz Thread Starter
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Default Builds By Baz - Metal/hybrid Wonder Woman armour

I recently took my wife to see Wonder Woman for her birthday and was thoroughly impressed that DC finally got a movie right.

I thought I'd make my wife a WW headband out of aluminium. I surprised her with it last night and she loves it.

Upon getting this far, I am seriously thinking about doing the rest of the costume for her.

Starting with the head band, I used screenshots from the movie, blown up on screen to a known face height, then used a ruler to scale it all directly onto paper, glued to thick aluminium sheet. The pieces were cut out using a hacksaw and filed and sanded into shape. I used a mill drill to cut a couple of fancy ledges in the centre piece. I will bend it into shape, rivet the larger pieces on then JB-Weld the star on in the centre.










Last edited by ASIGN_Baz; 7th July 2017 at 12:16 AM.
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Old 24th June 2017, 2:43 PM   #2
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Ooooo nice!!!
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Old 24th June 2017, 2:57 PM   #3
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At least there will be a lot less metal work with the Wonder Woman costume
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Old 24th June 2017, 5:45 PM   #4
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At least there will be a lot less metal work with the Wonder Woman costume
At least I can make the sword real....
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Old 24th June 2017, 10:44 PM   #5
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I decided on drilling and tapping to fix it all in place. Countersunk M4 machine screws, peined on the back then ground flush. Bent around the post anvil but will have to shape it specifically for the wearer later. Tonight I'll JB-Weld the star on.



Can't make noise in the shed at night so it's a bit of drawing to keep constructive. Arm band scaled from a screenshot and wifey's arm.

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Old 25th June 2017, 9:53 AM   #6
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Secured the stars with JB-Weld last night. After curing this morning, I have filled in and built the JB-Weld into all the cracks and gaps to solidify the stars as one on the crown. In 24 hours I can do a final trim, clean up and sand.

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Old 25th June 2017, 9:55 AM   #7
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A whole family of superheroes! Big time approval from your fans! What'll the kids be? Minions?
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Old 25th June 2017, 11:41 AM   #8
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But... But... Iron Man and Wonder Woman are from different universes. How will they ever meet???
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Old 25th June 2017, 11:49 AM   #9
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But... But... Iron Man and Wonder Woman are from different universes. How will they ever meet???
We actually discussed that yesterday. Wondering if Marvel and DC have ever discussed a merger in the future. Surely there's a way....

At least the colour scheme is the same. Red and gold.
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Old 25th June 2017, 2:29 PM   #10
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We actually discussed that yesterday. Wondering if Marvel and DC have ever discussed a merger in the future. Surely there's a way....

At least the colour scheme is the same. Red and gold.
Merger is highly unlikely. Historically there is a lot of bad blood between DC and Marvel. In a more contemporary context Marvel is owned by Disney and DC long ago hitched their wagon to Warner Brothers.
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Old 26th June 2017, 9:18 AM   #11
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That's cool Bazder Woman!

As for DC vs Marvel, it'd need third studio and licences up the wazoo!
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Old 26th June 2017, 11:03 AM   #12
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Wow, great effort, coming along very well
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Old 28th June 2017, 9:18 PM   #13
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Back to prototyping in cardboard. Wonderful stuff! Such a time and money saver! Freehand from a screenshot and wifey's wrist. I think I'll transfer this onto a sheet of thick aluminium, make up a couple of shaped steel punches and tool all the details in. Just like leather-work only hitting harder.



Making the bracers out of sheet aluminium and chiselling/punching the details in. Not entirely confident this will work out. It's going to take a lot of tooling. I have another idea if it doesn't work out.





So, aluminium and I just aren't good bedfellows. As per the Iron Man build, first tried aluminium and was really bad at it then decided on steel.
The grade may be wrong, the work hardening may have made it brittle and it needed annealing to work it further.
The chisel I used for details was too sharp and I probably was hitting it too hard. As soon as I bent it, all the chisel lines snapped.
The aluminium was also likely too thin. I can either make it again out of thicker aluminium, or accept defeat and move back to steel, half as thick. I'll try that tomorrow,





Traced it out on .95mm cold-rolled mild steel sheet this time. This is the same steel I used for the Iron Man suit. At least I know I can do lots with it. What's nice is that part of my suit's leftovers becomes one of the parts of my wife's costume.

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Old 30th June 2017, 4:35 PM   #14
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This method's a winner. hammered in the details with some custom punches made from mild steel bar and an old chisel shaped to suit.

The steel is half the thickness of the previous aluminium attempt, and marginally heavier. No biggie.







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Old 30th June 2017, 7:51 PM   #15
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Used alcohol ink to stain details in the steel.

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