"AND I'LL FORM THE HEAD!"



I purposely waited to make the Black Lion at the end of the build because I was looking forward to refining the techniques by building all the other Lions. It definitely paid off, I ran into so many problems before this point I knew what to look for.



Once again I started with the helmet… You know why lol. I framed it higher so there would be an empty cavity for the face to swing down. Pop-rivets were my best friend in this process; they helped with keeping it light weight.



The Process:

1. Frame the helmet

2. Make templates

3. Copy templates to wood

4. Make wooden mold (Vacuum form)

5. Sheet metal the jaw

The next step was making the chest/torso:

The process:

1. Cardboard the front and back and coat with Fiber Glass

2. Sheet metal the top shoulder and attach the front and back pieces

3. Make the shoulder boxes of foam and plastic coat it

4. Make the antenna of metal pipe and cover it with plastic coated foam



The only thing left was the hips and thighs



The process:

1. Get hockey pants

2. Vacuum mold the groin and butt pieces

3. make the thighs out of plastic coated foam

4. Attach