Prop building

Tools, Materials, Planning and Basic

Techniques

Part 1 – Two types of miniature hats

Table of Contents

• Safety• Tools• Materials• Paint & Print• Adhesives• Design / Research / References• Clip hat• Fascinator• Q&A• Raffle

Safety Guidelines

• Work in a well lit and well ventilated area

• Spray paint outside or in a painting booth and always wear a respirator

• Use the right tool for the job• When carving always push the blade

away from you• Dull blades/bits are dangerous, they

require more force and are harder to control

• A Dremel bit spins at 35,000 RPM – if you like seeing, wear goggles

Safety Equipment

• Face shield (starts from $5)• Goggles (starts from $1.5)• Gloves (about $0.15 per glove for

heavy duty nitrile gloves)• Respirator (starts from $16)• Dust mask (about $0.3 per mask)

$20 of safety equipment will keep you safe. What is your

excuse?Sources: Amazon, Harbor Freight

Proper Use of Tools

Always use a tool that is designed for the

material and the task at hand

So what tools do I need? AKA the Amazon wishlist

Phase 1: Basic tools• Scissors• Box cutter• Xacto knife• Respirator• Goggles/Face shield• Dremel + bits (reinforced

cutting discs and sanding drums)

• Drill• Drill bits• Coping saw• Hammer• Screwdrivers• Wire cutters• Needlenose pliers• Clamps (C-clamps & spring)• Files• Paintbrushes• Metal ruler• Measuring tape• Pins & Safety pins

Phase 2: Precision and leather• Combination square• Jigsaw

• Mallet• Auto punch• Vise• Caliper• Rotary punch• Awl• Precision screwdrivers• Hose clamps

Phase 3: Metalworking and beyond• More Dremel accessories

(Flex shaft, wire brushes)• More drill bits (rasp, wire

brushes, step drill bits)• Locking pliers• Tap & Die kit• Drill press• Scroll saw• Soldering iron• Heat gun• Multimeter• Hole saw kit• Jeweler's saw• Metal snips• Pipe cutter

• Sureform/plane

Consumables:• Sandpaper

(80/120/220/400/1000)• Steel wool• Painters tape• Zip ties• Nails• Screws• Paint thinner• Nitrile gloves• Wood filler• Permanent markers, paint

markers & pencils• Glazing putty and body

filler (Bondo)• Rags• Paper towels• Duct tape• Q tips• Toothpicks/skewers• Adhesives (full list on an

upcoming slide)• Paint

Recommended Materials

• EVA foam & craft foam – armor• Leather – armor, sheaths, straps, holsters• Sintra, Styrene, PVC, Plexiglass (Lexan)

and other types of plastic – armor, weapons

• Wood: know the different types - Hardwood, MDF, plywood, etc. – and dowels, in as many sizes as you can afford

• Metal: sheetmetal, pipes, candlesticks, chain, etc.

• Other: clamshell packages, hoses, cardboard, foam core, insulation foam, rare earth magnets, etc.

Paint & Print

• Acrylic• Spray paint – there are brands other than Krylon

and Rustoleum (automotive, graffiti, etc.)• Rub-n-Buff• Clearcoat – keep the paint on your prop and not

on your costume• Leather dye/antiquing gel• Tea, Espresso*• Overhead transparency• Adhesive labels• Dry brushing• Washes*Adam Savage weathering video: http://youtu.be/YXzxEqdvuIE

Adhesives

• White glue• Wood glue• Superglue• Mod Podge• Epoxy• Gorilla glue• Contact cement• Super 77 spray• E6000• JB Weld

The ultimate glue website: thistothat.com

…and before we start building…

• Create a plan/template:This can be anything from a list of measurements to a CAD design, whatever works for you

• Collect the materials/supplies:Try to have all the materials available prior to building, this includes paint and fabric

• Measure twice, cut once:Verify the dimensions after every step

• But mistakes do happen:if possible get extra materials or plan the prop in a way that parts can be replaced/maintained

Props for beginners

Start with a project that you can complete without having to learn too many new skills• Modifying an existing object, mostly

painting. For example, modified Nerf gun• Wand• Hat• Mad Moxxi’s megaphone• Jeweler’s Loupe• Steampunk pepperbox

Build No. 1a – Clip hat

Rationale:• Low cost materials• Emphasis on finishing techniques,

not on construction techniques• Minimum investment in tools and

materialsTools:• Scissors• Sandpaper• Pen/Pencil/Sharpie

Build No. 1a – Materials

• Cardboard – cereal boxes• Bottle cap• Glue (E6000, hot glue, white glue,

wood glue)• Hair clip/bobby pin• Ribbon, gears, flowers, buttons,

feathers, costume jewelry, etc.

Build No. 1a – Template

• Cardboard brim – 2.25” diameter• Bottle cap – twist-off cap. Roughly

1.125” diameter• Optional - Ribbon around the crown

of the hat – 3.625”, depending on the size of the cap

Resources:http://youtu.be/flcOTra3PaQ?list=UUt4zycubX8BJZ8pZhZ4w8owhttp://wonderfuldiy.com/wonderful-diy-hat-hairclip-out-of-plastic-cap/#

Build No. 1a – Construction

1. Create the brim – attach 2 layers of cardboard

2. Cut to size – tips for round templates: vitamin bottles, rolls of tape, spray paint cans,

3. Seal the edge4. Prime cap and both sides of brim5. Glue cap to center of brim – try to minimize

the amount of visible glue to ensure a clean seam

6. Paint it and seal with top coat7. Decorate!8. Attach clip or bobby pin

Build No. 1a – Finishing Surfaces

• The purpose of primer is to help paint adhere better to the surface and provide a uniform appearance. A primer also prevents color from bleeding through and messing up the appearance of the paint

• Many thin coats of paint work better than a few thick coats

• Uneven surface after painting? Drips? Sand it down• Once the painted surface is even, use higher grit for

each additional coat. If you plan on having a glossy appearance you would get the best result if you sand the second to last coat with 1000 grit or higher

• Acrylic paint doesn't sand as well as lacquer• Always seal your paint...• ...but multiple coats of clearcoat may alter the

appearance of your paint (change glossiness or add a “milky” layer on top)

Build No. 1a – Tips and Tricks

• Hose clamps create a perfectly round shape and can be used to attach things to round shapes. Zip ties are an alternative to hose clamps

• For perfect placement of the cap, you can print a circle of the same size as the cap on cardstock and use the cardstock instead of one layer of cardboard

• Spice bottles, thread spools (mad hatter thread spool hat?), PVC pipe – many other materials can be used for the crown

• Prefer a different shape? square (Companion cube), cone (witch’s hat)

Build No. 1b – Fascinator

• Rationale and tools are the same as in version 1a

• Materials can be the same but if you want to advance your skills, instead of painting, cover the fascinator in fabric, leather or textured paper

• Due to the additional weight a single clip may not be enough so use two clips, a headband, a ribbon or a comb

• Decorations: the larger scale adds more options. Playing cards, tassels, goggles, toys, keys, etc.

Build No. 1b – Tools, Materials & Resources

Tools:• Scissors• Xacto knife• Sharpie• Hot glue gun• Printer (optional)

Materials:• Cardboard• Fabric• Super 77 spray

adhesive• E6000• Hot glue• Card stock (optional)Resources:

https://coalfusion.files.wordpress.com/2015/07/fascinator.pdfhttp://www.fleecefun.com/mini-top-hat.htmlhttp://fashion.onblog.at/en/diy-advent-9-small-burlesque-hat

Build No. 1b – Suggested Dimensions

Small:• Top of crown 2.625” diameter• Bottom of crown 2” diameter• Height of crown 2”• Brim 4.5”Medium/Large:• Top of crown 3” diameter• Bottom of crown 2.5”• Height of crown 2.375”• Brim 5.5”

Build No. 1b – Construction

1. Create the cardboard parts according to the pattern

2. Attach fabric to brim, crown and top3. Form the crown4. Attach the brim to crown5. Attach the top to crown6. Decorate7. Attach the clips/ribbon/comb/headband

Online resources and Communities

Communities/ForumsThe RPFCosplay.comThe dented helmetBrass Goggles

Blogs/VideosTestedPunished PropsVolpin PropsPropnomiconEvil Ted SmithStiltbeast Studios

RetailersMcMasterGraingerFastenalTandy LeatherHarbor FreightAmazon

Q&A

Raffle

End of Part 1