Buff, NY Working with Worbla

Discussion in 'NorthEast Regional Discussion' started by 72Princess, Mar 26, 2013.

  1. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    Several of us have recently acquired WORBLA, a fantastic material that can be heated and molded, reused, painted, shaped, etc.

    I wanted to start this thread to share experiences, success and failures of working with this wonderful material.
  2. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    Here is a quick and basic tutorial: LINK
    Last edited by 72Princess, Mar 26, 2013
    BPStoyle likes this.
  3. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    After some trial and error, I have the framework for my Boushh armor complete! Now to work on the collar portion before filling, sanding, priming, painting....
  4. jediprof Jedi Grand Master

    Member Since:
    Jul 14, 2009
    star 4
    Really interested in seeing your work on this, Anna. It would be great if you could document the stages or post some pictures so we could see the process.
  5. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    I dont have an online account that would permit me to post photos... :confused: I have been taking photos throughout the process. I'll see what I can figure out.
  6. BobaChris12 NE RSA & Buffalo, NY CR

    Manager
    Member Since:
    Aug 30, 2002
    star 9
    Anna, try taking them with your iPhone. I was able to upload pictures right to the forums using the tapatalk app.

    Can't wait to see your progress. Very curious to see if this process can be used for other armor.
    72Princess likes this.
  7. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG]
    [IMG]
    Measuring with paper. (I used newsprint)
  8. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG]
    Using the paper template for the foam then measured the foam one more time on the dressing form.
  9. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG][IMG]
    More trimming and sizing of the foam
  10. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG] Placing the foam on the worbla. I missed the step of heating the worbla first. Instead, I made a foam, worbla sandwich then heated both sides. It worked, but I think it was more work and would be better by heating the worbla, placing foam, the covering w worbla and heating the other side. [IMG][IMG]
  11. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG][IMG]
    The form for the base of the armor. I am holding the front down as it will be connected to a comlink. Starting to work on the collar tonight. The front will be turned up, the collar will be an additional piece. [IMG][IMG] my end goal- or something close...
  12. BigDanLevitan N.R. Vice President

    Chapter Rep
    Member Since:
    Jun 26, 2005
    star 5
    What type of foam are you using for the middle of the worbla sandwich?

    Looks awesome BTW! I can't wait to start messing around with the stuff I bought.
  13. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    The foam I am using is actually a headliner foam I bought in a large roll at Joanns. Most tutorials recommend a craft foam. All I could find is 8 1/2 X 11 sized sheets at Joann fabrics.
    The thicker foam has left my armor a bit flexible, which works for this particular project, but I would not recommend for a solid type of armor (example a MANDOLORIAN) . I also wanted the thicker foam due to the thickness necessary for the armor. The "Worbla sandwich" is recommended thought, the material is too thin to shape well in one layer and it tends to show every little detail, finger print, bubble, etc.

    I think I am going to use the craft foam for the collar and the ridge around the front of the armor.

    I would also recommend a large heat gun. I tried using my small one I used for embossing and it was simply too small. I bought a nice big heat gun at Home Depot for $25 in the paint section. It has made all the difference in the world!
  14. BigDanLevitan N.R. Vice President

    Chapter Rep
    Member Since:
    Jun 26, 2005
    star 5
    I will have to invest is some of that foam you describe before I get to work n my project. Thanks for doing this thread I'm sure it will help us all out!
  15. jediprof Jedi Grand Master

    Member Since:
    Jul 14, 2009
    star 4
    This looks awesome, Anna!
  16. BPStoyle Jedi Grand Master

    Member Since:
    Jan 5, 2010
    star 4
  17. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG]
    [IMG]
    Shaping the collar and molding the front. The wonderful thing about Worbla is it is so easy to mold and manipulate. It stays pliable for several minutes after heating so there is time for "tweaking". I used the styrofoam block to hold the shape while the Worbla cooled.
  18. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG]
    [IMG]
    [IMG]
    The collar is attached! The Worbla has glue on one side. I shaped the foam, cut and heated the Worbla accordingly, then attached it to the outer form of the armor. I did this so I can "sandwich" the collar into place.
  19. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG]The inside of the collar.
    [IMG] The interior layer before the Worbla was heated and pressed into place. In order to have the glue side facing the right way, I had to use and cut my pattern upside down.
  20. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    [IMG]The collar is on!

    With all of the heating and manipulation, the front edges were altered and "bent out of shape". I will need to fix that next but I know it will not take long.
    The right side of the collar has a fold I could not smooth out. Once I fix the front, I am hoping I can fill that one side so it will not be as obvious.
    BPStoyle likes this.
  21. BobaChris12 NE RSA & Buffalo, NY CR

    Manager
    Member Since:
    Aug 30, 2002
    star 9
    Great job Anna!
    72Princess likes this.
  22. MakanPyralis Force Ghost

    Member Since:
    Aug 16, 2005
    star 4
    = impressed!
    you are doing an amazing job!
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  23. Darth Erebus Jedi Master

    Member Since:
    Sep 2, 2012
    star 2
  24. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    you should see it now!! I am SO PROUD!! Pics to be uploaded later... :D
    Last edited by 72Princess, May 15, 2013
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  25. 72Princess Force Ghost

    Member Since:
    Jun 15, 2010
    star 4
    For anyone working with Worbla, Joann Fabrics now has rolls of craft foam! Great for this larger projects!