Texelsaur π MegaplexWrapping the wing in fabric, and a comparison to the original wing. The shape is different and I think more accurate to the game model.
For extra support, a carbon fiber rod was run along the spine of each wing, held in place by wrapped thin wire.
The perimeter of each wing was wrapped in foam, like before, to help float the fabric over the frame.
The new wing frames were built more like a truss to eliminate flex at the joints.
The joints themselves I went a bit overkill on to make sure they wouldn't fail. I also had to move up to a propane torch to properly solder these.
Here's the wing uppers mounted in their bases.
The new wings would have a 3D-printed base where the steel wire could securely mount in places, and it would slide onto a spline post to mount. An embedded magnet inside would help secure it if the post was angled sideways, as it would be when the wings are kept in the downward
"safety" position.
As a bonus, the green filament I found was almost a perfect match for the fabric I was using.
Alright, MAG 2019 was fun, but I wasn't fully happy with the chest piece and one of the wings was sad and broken by the end of the weekend.
The hinge concept was durable, but didn't work great in practice. Keeping the wings partially extended out involved a crude hack of shoving dowels in the hinge and holding them in place with rubber bands. They were hard to mount and required a screwdriver.
I started prototyping ideas and realized a spline could give me multiple locking positions. And an L-connector could give me rotation on two axes. I also just got a 3D printer...
To support the weight and leverage of the wings, a steel plate was mounted inside the body piece with some threaded inserts. This distributes the force across most of the back, which is sufficient to hold up the wings.
And here's a test mount before I flipped the fabric inside out and finished them. I actually never cleanly finished the base of these. After MAGFest 2019, I got to work on a complete replacement of the wings and chest, which will be the next topic...
The outer edge of the frame was wrapped in 2mm foam, which allowed the spandex to "float" above the frame, making it less visible.
Time to finally get to wings! I started with a round of prototyping materials (the intention in each case was to wrap with fabric). The foam was an immediate no-go, and I settled on a steel wire frame.
I had two requirements for the design: I should be able to mount them horizontally or vertically (pointing down), and they should be able to swing back if someone hits them.
I sketched out a design using cabinet hinges and a cross bolt pattern.
The engineers should note how bad my "wing truss" design is, plus the very weak solder joints. You'll be happy to know these did not hold up.
I don't have many WIP pictures of the scythes finishing process. I don't remember if I plasti-dipped any of it.
Finishing the foam involved cutting in the edge of the blade, and carving in the center line.
The top was formed with 2mm EVA foam, and the cuff was formed from the softer green foam. All wrapped in spandex and sewn and glued in place.
Silver paint finished them out.