In PART 1 of his 3-part "How to Make a Sci-Fi Helmet" course series, master artist & model maker, Fon Davis (STAR WARS 1-6, GUARDIANS OF THE GALAXY, INTERSTELLAR) teaches you, step-by-step, how to build a low-cost custom vacuum form machine (aka Vacuform) for your character costumes & cosplay projects.

This DVD is a 2-Disc Set

Intermediate Level

7h 25m of duration

English (auto), Spanish (auto)

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Curriculum

1. Title & Introduction - 23min

2. Breaking Down the Vacuum-Forming Machine - 36min

3. Building the Heat Box - 56min

4. Making the Heat Box Cover - 8min

5. Building the Power Circuit - 29min

6. Wiring the Switch & the Vacuum - 29min

7. Working with Metals to Build the Frame - 7min

8. Cutting & Welding the Metal Frame - 47min

9. Building the Vacuum Box - 32min

10. Shopping for Greebles - 11min

11. Prepping Parts for the Heat Sink Box - 31min

12. Building the Heat Sink Box - 27min

13. Mounting the Supports - 56min

14. Assembling the Vacuum-Forming Machine - 43min

15. Discussing the Design Process - 2min

16. Reference Materials - 8min

17. Day One Wrap Up - 43s

Materials

CLICK on the links below to find the materials you need for this lesson.

Some items might be harder to find, but a little internet scouring usually finds you everything you'll need.

McMaster Carr

VACUFORM MACHINE

Please Note: The Alt links have been provided for international students

2 Space Heaters 9 x 12 (need a reflector and flat ribbon heating element)

Alternative 1: to the space heaters 20' Nichrome ribbon and custom made firebrick wire mounts)

Alternative 2: Toaster oven

1' Roof Flashing 20" tall alt: Sheet tin

12' High Temp Cloth Insulated Oven Wire alt: High Temp 12 gauge wire

3 Way Toggle Switch High Amperage alt 3PDT Switch

Thermostat

10' 1" x 1" L Channel alt: L Channel

10' 1/2' x 1/2" x 1/2" C Channel alt:C Channel

14' 1/2 x 1/2 Square Tube alt: Square Tube note: the alt stock is 3/4" some adjustment will need to be made to the design

1/4" Wing Nut alt: Wing Nut

1/4" x 3" Hex Bolt alt: Hex Bolt

1/4" Large Eye Bolt alt: Large Eye Bolt

16' 1/2" High Temperature Weather Seal alt: Seal note: the alt product will need to be trimmed lengthwise to .12.7 mm strips

6' 1/2" Magnet Strip alt: Magnet Strip

6' 1/2" Flat Stock alt: Flat stock

1/8" 6061 Aluminum 14 3/4" X 10 3/4" alt: 6061 Auminum

3 Project Sheet 3/4" Plywood alt: MDF

(4) Screw On Rubber Feet alt: Rubber feet

4" Intake Vent alt: Intake Vent

24 Pan Head #4 Wood Screws alt: #4 Wood Screws

1/8" x 1/8" Pop Rivets alt: Blind Rivets

1/8" x 1/4" Pop Rivets alt: Blind Rivets

36 Drywall Screws alt: Drywall Screws

Silicone Caulk - Window and Door alt: Decorators Caulk

2 HP Shop Vac

Box of Wire Nuts

BUILD MATERIALS

(10 pieces) Floral Foam 4 x 9 x 1

(24 pieces) .06 styrene sheet 12 x 16

(24 pieces) .03 styrene sheet 12 x 16

Greeble (varies by project)
Garden centers
Tower hobbies
Plastruct

PAINTING MATERIALS

Airbrush

2 Spritzer Bottles

2 Chip Brushes

Assorted Model Paints (model master, testers) varies by project we will be using: gun metal silver, black, grey

Latex House Paint, for distressing varies by project we will be using: light grey, black, brown

99% Alcohol

ELECTRONICS

Assorted single or multi-color leds (varies by project)

24 guage black wire

HEALTH/SAFETY PRECAUTIONS

When working with toxic and/or dangerous materials or tools:

ALWAYS read labels for appropriate use guidelines

ALWAYS wear a high-grade respirator

ALWAYS work in a well-ventilated area

ALWAYS protect your skin

ALWAYS wear eye protection

Artist BiographyFon Davis

Fon Davis Model Maker, Creative Director

See Full Bio

Additional Purchasing Options

Notice: DVDs do not include closed captions.

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