self-made ROTJ decals

[TKCaleb]

I had been tinkering with the idea of creating my own screen accurate decals.. I think it needs some fine tuning here and there, but overall not too shabby.

 

 

 

 

For those who have not seen ROTJ decals, here are some pics.

 

I plan to use a finer mesh when applying the paint to the vinyl. I also plan to use flat paint next time around, not satin.

 

What do you think??

Edited November 21, 2011 by TKCaleb

[ZeroRoom[TK]]

Wow! Dude - that's seriously great work. Really captures the screen printed textures of the originals. Did you roll the stencils or squeegee them?

[TKCaleb]

Thanks. I used a squeegee. But I had to dry off the paint, then apply another layer to build it up to the proper thickness. Its quite exhaustive.

I'm trying to figure how ILM did the decals. The pattern is certainly not silk screened through. I've tried silk screening the decals, but it was an utter failure. I strongly believe they had transferred the paint onto a layer of vinyl through means of mesh or silk screen, to keep an even coat, then had them either die cut or hand cut following a template. After word, it would be applied on top of a solid layer of matte black vinyl which was then cut out free handed with a blade or scissors.

 

At least, that's my theory, and its pretty much what I did here.

Edited November 21, 2011 by TKCaleb

[TKCaleb]

I think I gave up to quickly on the silk screen method, Im going to talk to a professor of mine tomorrow who has a MFA and has done print making as a career back years ago. He is truly a master, so he may have some good suggestions on how to properly achieve the screen accurate decals without all the cutting.

[ZeroRoom[TK]]

In what way was the screen printing an utter failure? (I have some experience with screen printing - might be able to help)

[TKCaleb]

In what way was the screen printing an utter failure? (I have some experience with screen printing - might be able to help)

 

 

It was most likely user error, but I masked off my screen with drawing fluid, which was used to fill the design of the decals, then I used screen filler for the negative space. After I rinsed the drawing fluid, I went to test out the screen. Once I lifted the screen, I had nothing but epic blotchiness. the print looked like decals with a Gaussian 20px blur applied to it. There were no well defined lines, or anything.

[ZeroRoom[TK]]

Ahhh - exposing screens without a UV lamp is prone to disaster.

 

I would recommend you try a thing called a Riso screen. You can get them made at most local art supply stores.

 

Basically it's like an inkjet printer that uses heat to expose a stencil on a thin mesh coated in plastic. If you provide a laser copy of your artwork they copy it onto the Riso mesh in seconds. This is the machine:

 

http://www.screenprintingshop.com/shop/screen-printing/machines/TCA3-SP

 

Or you could buy one of these miniature home use ones if you were really commited!

 

http://blog.tramdang.com/2010/05/10/a-quickie-on-the-riso-gocco/

 

Then all you have to do is stretch the stencil onto some sort of frame and go ahead. It will last many uses and produces a result almost as good as a professional screen for a tenth of the cost.

[TKCaleb]

Thanks a lot man! Ill definitely try that out!

 

Stay tuned for updates.

[TK bondservnt[501st]]

one has been discontinued!

[TKCaleb]

Added them on to my CFO bucket.

[ZeroRoom[TK]]

Wow that really does look good! Nice work. I'm looking to get a CFO lid so I'll have to remember this technique. Thanks for posting it up

[darksideemt]

I know it's not, but in the close ups the texture on the gray looks like duct tape. Good luck with your fine tuning.

[TKCaleb]

I know it's not, but in the close ups the texture on the gray looks like duct tape. Good luck with your fine tuning.

I said the same thing to myself after making them. Im making more tonight, hopefully they will look correct.

[TKCaleb]

UPDATE

 

I picked up a can of flat/matte paint today after work, reformulated the color to better match the CFO decals, as the first can of paint was to gray.

 

Old satin paint on left, New flat/matte paint on right.

 

 

and some pics of the decals when applied to the helmet

 

I think I am getting closer and closer to making these look as screen accurate as possible. I am still planning on making a proper stencil and silk screening these bad boys..

 

Caleb

[ZeroRoom[TK]]

That blue-grey is a big difference isn't it? Looking really good dude. Well done

[TKCaleb]

Big difference! The original paint I was using looked to ESB. The flat finish also adds a lot to the finished look of the decals, due to the fact that the black vinyl layer has a bit of sheen to it.

 

Caleb

[Verne]

These declas looks perfect!!!

[TKCaleb]

Thanks Vern, they will be perfect once I properly learn to silk screen, cutting each piece out by hand is just not feasible.

 

Caleb

[Turrican]

Wow, they look realy cool.

Like the semilar texture to the screen used ones, good work.

[sskunky]

You can put me down for a set........ In fact I may commission you for some sets for me? If you like ?

[TKCaleb]

You can put me down for a set........ In fact I may commission you for some sets for me? If you like ?

 

 

PM sent man.

[AJCG]

Great stuff Caleb...It is looking great my friend! your hard work is paying off...too bad I do not have any ROTJ lead anymore

 

Cheers

 

A

[TKCaleb]

I finally went by the printers and made up some tube stripes. I also made 4 sets of decals last night. Applied one of them to try out on my helmet, they look much better than before.

 

 

 

Please excuse the cheap helmet stand.

[TKCaleb]

Great stuff Caleb...It is looking great my friend! your hard work is paying off...too bad I do not have any ROTJ lead anymore

 

Cheers

 

A

 

Thanks Armando! I thought you had a hero helmet? You sold off that one too?!?!

[AJCG]

My pleasure...they look very good. Nah I let it go long ago...to many helmets at home and I need to reduce my collection before I moved back to SF