Casting my legs

[James B.]

Ok so it is time for me to cast my legs for custom armor.

The best suggestion I have got so far is to do plaster bandages, cut the cast down the back and add andother layer to the back to seal it.

Anyone know of something better?

Thanks

[Lord Ogier]

Is this anything like concrete overshoes???


I think you may be able to buy the wraps that doctors use for casting broken limbs. It is basically a fiberglass bandage with resin impregnated in it.

You might look into this.

[Fujiwara]

Warning: LONG

I would recommend against the fiberglass method, mostly because its messy. Plus, doctors put a very thick sleeve over the broken limb when using the fiberglass, as it is very irritating. This would grossly distort any cast you would be making. I would go ahead with the plaster bandage method, as sculptors and SPFX makeup artists use plaster to make moderately detailed molds of large body parts. I have two recommendations:

1) Use LOTS of Vaseline, unless you plan on shaving your legs

2) Rather than possibly destroying the mold by cutting down the back, do the front half of your leg with 3-4 layers, let it cure, then brush Vaseline thickly along the edges in a band about 1.5 inches wide. Do the back half in 4-5 layers, overlapping the front by an inch or so. Let that cure, then CAREFULLY pull the two halves apart. Voila! A mold of your leg with no damage. Paint the inside with an even layer of Vaseline, or spray with silicone mold release, and put the halves togther and hold them together with wire ties. Plug up the bottom with clay and pour in your casting agent (plaster of Paris, hydrocal, whatever). Let THAT set (2-3 days) and you're done. I have seen plaster bandages at the local craft store in 8" widths, wich would be ideal for something like this. Hope this helps!

[James B.]

Fujiwara

I got the same recommendation in a privet email too. I think I will go that way. Also on the shave/Vaseline I am why ahead of you, I have a gel for that from a sculpting company

Thanks

[Sixtus_Goetz]

James,

Have a quick down and dirty method that is fairly safe and clean.

Get some thin pajama bottoms. Get in whatever position you want to be in and have someone start to lightly tape your leg. I used duct tape with realy good success. Do a few layers to get it somewhat ridgid. Mark lines horizonal a few places down your leg. Take scissors and slip it between your skin and the pajama's in the middle of these lines. When you have the casting off, line up the lines and lightly tape them back together. You will have a casting of your leg that is aprox 1/16"-1/8" larger then your leg. You It is dooable with one person, but two makes it go that much easier.

I did this with MRKS and he said it helped his job out alot.

Cheers

[wbf]

James,

Have a quick down and dirty method that is fairly safe and clean.

Get some thin pajama bottoms. Get in whatever position you want to be in and have someone start to lightly tape your leg. I used duct tape with realy good success.


Cheers

Thats the way some dress makers said to measure my wifes dress for the ahem, top half...

I would think that would be the best way.. It would also cut down on the cost for shipping.. Since the duct tape is lighter than plaster casts..

[Kenwrec Wulfe]

Grab a cheap pair of leggins (hose) or some such from Walmart. Put them on. Duct tape a few layers for stiffness. Slit to remove. Retape. Use the expandable spray foam (Home Depot) to fill. Gives a solid reletively accurate leg shape.

[James B.]

Thanks guys but I don't think the duck tape method will hold up in the plaster cast phase. I want the armorer to have a perfect copy of my legs to get the greaves just right.

[Ringlancer]

Cut your legs off, slightly below the knee. Using a very hot iron, cauterize both open wounds.

Pack the legs in ice and ship them to your armourer...he will then beable to work with your legs and get the best fit possible.

Once he is done, take your legs back and have them reattached. There might be some slight numbness afterwards, but you won't have to deal with messy plaster.

Good luck!

[Hew]

Cut your legs off, slightly below the knee. Using a very hot iron, cauterize both open wounds.

Pack the legs in ice and ship them to your armourer...he will then beable to work with your legs and get the best fit possible.

Once he is done, take your legs back and have them reattached. There might be some slight numbness afterwards, but you won't have to deal with messy plaster.

Don't be silly. Leave the meat legs off and just install the steel legs. Prosthetics are cheaper and easier than limb reattachment.

[Sixtus_Goetz]

Thanks guys but I don't think the duck tape method will hold up in the plaster cast phase. I want the armorer to have a perfect copy of my legs to get the greaves just right.

Another suggestion. Try it, doesn't take long and MUCH less messier. And if it doesn't work, then go your prefered method. I found it give a very good representation what is formed.

Cheers

[Alcyoneus]

Paper mache?

[RalphS]

Just a few more options, a bit more high-tech:
http://www.leica-geosystems.com/metrolo ... s_1806.htm
http://www.radiologyinfo.org/content/mr ... eletal.htm
http://www.vialux.de/egc1.htm

The big advantage is that you cut down on mail costs, since you can e-mail the scans to the armourer. The disadvantage is that the equipment is perhaps a bit more expensive than plaster.

[Laurie Wise]

Whatever method you use, do be sure your bare legs are protected.

Kirby learned this many decades ago when he made his first pair of fitted full greaves for a friend. He used plaster of paris and neither one thought about vaselining or wrapping the lower leg being cast. The result was the poor guy had his shin hairs pulled out. OUCH!

So, pantyhose was used next time without any problems. Any succeeding ones were made the same way or, if the customer could not come by, had the casts done using the plaster wrappings. Then sent the results to Kirby to make the forms from.

[Anon001]

deleted

[eoghan_mw]

and how about using linen or cotton scraps, cut them, shape them, customize them to the shapes you need. Buy cheap cloth from wally world...

[James B.]

Another suggestion. Try it, doesn't take long and MUCH less messier. And if it doesn't work, then go your prefered method. I found it give a very good representation what is formed.

I am shipping the plaster cast of my legs to the armored to let him make the plaster mold. I figure the plaster bandage cast with last better in transport than the plaster cast of my legs would. This is why I want something so strong. Time is of the essence too, can’t afford to try unknowns.

Ingrid thanks for the tip but I need it this weekend so I am going to make a trip to the art store tomorrow.

[Guy Dawkins]

James, you need to send the armourer a positive cast of your legs. Just sending the cast made from the bandages that were wrapped and cut fromm you legs will be a negative. The number of wraps that would hold up to shipping will probable be too thick.

After you have made the negative and cut them from your legs coat each half with plaster backed with bandages for reinforcement. When this positive cast is dry, join the halves with plaster bandages.

Good luck, and let us know what you did and how it worked out.

[James B.]

James, you need to send the armourer a positive cast of your legs. Just sending the cast made from the bandages that were wrapped and cut fromm you legs will be a negative. The number of wraps that would hold up to shipping will probable be too thick.

My plan is to ship the negative so he can make the positive. I have heard lots of stories on the the positive is breaking in shipment.

Good luck, and let us know what you did and how it worked out.

Will do.