
This past weekend I went to a steam punk themed wedding for my really good friends Shelby and Andrew (Congratulations guys!). When they first announced the theme a little more than a year ago, I was requested by the bride to attend wearing a robot arm ("Wright, it wouldn't be my wedding unless you had a robot arm"). So, never one to disappoint, I built The Blusterbuss.
I based the arm around the one used by Gwen, the character I posted here a while back.
I started with a hockey glove (easy to procure in Canada) and built it out from there. The glove opening was three inches, my forearm was eight, etc. I estimated most of the measurements, and they worked out, though my Perspective teacher will probably kill me for not drawing an orthographic projection...
Both Evil FX and the Volpin Props had made extremely cool N7 armor from Mass Effect 2. Each were raving about this stuff called EVA foam. You may recognize that as the squishy playground floors with the puzzle piece edges. Even though Mass Effect and steam punk are as opposite as you can get, I decided to use EVA foam. Unlike the N7 armor, I used the untextured side.
The foam didn't disappoint. It was very easy to work with, lightweight, and most importantly, cheap. I got eight 2' x 2' squares for $20, and I still have six sheets left (so I might just try my hand at making that Mass Effect armor).
I measured out all the individual pieces, beveled the edges, and put them together with rubber cement. The one thing I had to get used to with the foam was how soft it was. It could be cut without trouble with a thin bladed band saw, but the belt sander just ate through it and I had to use a Dremel on the lowest setting. There were a few nicks, but overall it worked.
I wrapped the whole thing in thick poster board and filled in any gaps and imperfections with acrylic modeling medium, a thick, quick drying paste. I sanded it down, but kept some of the texture because it looked like welding joints when painted with Hammered Silver spray paint.
All that remained was embellishing, weathering, and adding lights.
My basic technique was spray painting the piece and then dusting it with another color. If I painted it hammered silver, I dusted it with hammered bronze and vice-versa. This gave it both a metallic and a rusted look. Then I took some gold acrylic paint and applied it lightly with a piece of steel wool. Afterwords I scratched it up with some heavy grit sandpaper, applied actual dirt and mud, and in some cases beat it with a dull machete that just happened to be lying around.
The bronze strips are craft foam. The box on the top of the arm was going to be filled with electronics as well as the plastic tube, so I didn't want bolts in the way. Instead of buying a big bag of screws and cutting them down, I decided to buy one bolt and cast the head in resin.
I pressed it into a block of clay several times, and poured in the resin. It was my first time using the stuff, and the biggest thing I learned was to have a measuring cup that does ounces handy. The mixture of resin to catalyst needs to be relatively precise. I eyeballed it and it took a couple of tries to get it drying right. Like all the other pieces, I sprayed the bolt heads in paint and dusted it with bronze and gold.
Afterwords, I partook in my favorite pastime, going to Home Depot to find stuff that looks like other stuff.
A ceiling bracket, toilet o-ring, some tubing, and
a neat clock face that I cut the numbers off of.
All that remained was embellishing, weathering, and adding lights.
My basic technique was spray painting the piece and then dusting it with another color. If I painted it hammered silver, I dusted it with hammered bronze and vice-versa. This gave it both a metallic and a rusted look. Then I took some gold acrylic paint and applied it lightly with a piece of steel wool. Afterwords I scratched it up with some heavy grit sandpaper, applied actual dirt and mud, and in some cases beat it with a dull machete that just happened to be lying around.
The bronze strips are craft foam. The box on the top of the arm was going to be filled with electronics as well as the plastic tube, so I didn't want bolts in the way. Instead of buying a big bag of screws and cutting them down, I decided to buy one bolt and cast the head in resin.
I pressed it into a block of clay several times, and poured in the resin. It was my first time using the stuff, and the biggest thing I learned was to have a measuring cup that does ounces handy. The mixture of resin to catalyst needs to be relatively precise. I eyeballed it and it took a couple of tries to get it drying right. Like all the other pieces, I sprayed the bolt heads in paint and dusted it with bronze and gold.
Afterwords, I partook in my favorite pastime, going to Home Depot to find stuff that looks like other stuff.
a neat clock face that I cut the numbers off of.
The pressure gauge is my favorite part and the piece de resistance that really made the arm steam punk. It's made of a water pressure testing gauge, some brass piping, and a shower drain. I had a lot of fun antiquing the gauge, going to town on it with sandpaper and paint, even at one point smashing it on a rock.


Gauge detail. I really like the little lines of gold paint.
For the light tube I coated the inside with several layers of resin. I turned the tube as it dried to give it a warped "filled with liquid" look. Then I coated the inside with a few layers of frosted spray paint to make it opaque. I rubbed the outside with sandpaper to both make it look banged up and make the light even more diffused.
I'd like to say that the lighting was something special, but it was just a cool flashlight I found that had settings for red, blue, and white light. I glued it into the tube and cut a little door so I could reach in and change the color of the light on the fly.
Blue.
Red. It looks much better in the dark (see the first pic).
White.
I'd like to say that the lighting was something special, but it was just a cool flashlight I found that had settings for red, blue, and white light. I glued it into the tube and cut a little door so I could reach in and change the color of the light on the fly.
I ordered a bunch of electroluminescent wire that I was going to use to light the arm, but my shipment didn't arrive on time. As of writing, it still isn't here. Let's hope it gets here before Halloween. I ordered it a month ago...
I still have a little more modifications to do. There are a couple bits I need to reinforce, maybe I'll add a few more bolt heads, and I want to install the EL wire, but otherwise, I'm incredibly proud of this. It was the most professional prop build I've done. It was very light-weight (weighing in at a surprising three pounds!), comfortable, durable (survived two full days of partying), and most impressively, it was functional. With that big glove I was able to eat, smoke cigars, play pool, and daintily hold champagne flutes and beer glasses.
Plus the wedding party commandeered it for their official photos. I can't wait to see those!
I still have a little more modifications to do. There are a couple bits I need to reinforce, maybe I'll add a few more bolt heads, and I want to install the EL wire, but otherwise, I'm incredibly proud of this. It was the most professional prop build I've done. It was very light-weight (weighing in at a surprising three pounds!), comfortable, durable (survived two full days of partying), and most impressively, it was functional. With that big glove I was able to eat, smoke cigars, play pool, and daintily hold champagne flutes and beer glasses.
Plus the wedding party commandeered it for their official photos. I can't wait to see those!

























