Tag Archives: hobbies

Stupid hobbies again: The Juggling Box

The first plan, taken from my planner.

When I get busy with things I have to do, my brain will squirm like a bored toddler and suggest stupid hobby stuff instead. I waste a lot of energy arguing with myself that I don’t need a pedal powered landspeeder, don’t have room to store one, even if I knew what to make it out of, and the steering would be a real issue, though I guess we could knock up a variant of rack and pinion and…

This is how I get into trouble.

Right now it’s pretty bad because I have a suit of Clone Armour (From The Bad Batch, coming soon to Disney +) that needs a complete overhaul. I have a dalek that needs surfacing work, and a ton of electronics. I have a helmet I’ve started for Mrs Dim, the first costume she’s expressed interest in wearing, and there’s loads more to do on that. Oh, and I started a rough project to build a Hollow Knight mask for my youngest Weasel.

All of which means, along with my day job and the paid writing work, that I have plenty to do, thanks very much Brain.

So a couple of weeks ago my brain started sketching out ideas for a new juggling box (see the illustration at the top.)

I know the kit I need for the kind of show I do these days, so I made a list and began to imagine the box I would need to hold it all. Since I didn’t have any way to measure the clubs and stuff, I used Z as the length of the clubs, and X as the depth, and Y as the width of all five of them together. All the other parts of the box would be measured in relation to those distances.

Don’t worry if none of this makes sense, it’s just what I do to keep my brain happy.

After a couple of weeks, it became clear that my brain wasn’t going to let go of this one. Never mind that I haven’t had an actual juggling gig in over a year, never mind that there’s nothing wrong with the kit transport that I have now. Oh no, we must make a box, my precious, and it must be very, very complex!

I bought wood. I wanted to buy piano hinges as well, but obviously they don’t make those the right length. In fact, of all the things I went to buy at Home Depot, the only bits I actually found there were the wood (2ftX2ft project panels) and some all-purpose tool holders that were going to be used to clip the clubs into place inside the box.

I didn’t photograph the early stages because it went very quickly and I didn’t have any hands free. First, construct a box with all the correct dimensions. Check those dimensions very, very carefully. Get corners as close to 90 degrees as possible. Then very, very, VERY carefully, cut all around the middle of the box, and really, really hope you picked the right side to start. Then, cut one of those pieces in half on the other dimension. Now, go look in that box of hinges and see if you can find four the same.

Ok, well, are there two the same?

Good.

Are there another two that are the same as each other?

Ok then. Put two hinges on each side, and now you have a box that opens along a central seam! I put the tool holders in place in the back and the clubs fitted in as if I had measured. (Which I had. Again and again.)

This would have been a good place to stop. I had achieved something, and my brain was a little surprised. Maybe it would have left it at that, but now my confidence strode to the fore and said “This is JUST the beginning!”

Because there’s more than clubs, right? You saw the list I made. By putting in guard rails on either side, and little restraining rails on the bottom, I could put juggling knives in one side and fireclubs in the other, swinging out like some magical thing!

I also made a box to sit on the top that would hold all the juggling balls.

And this was good, and I was happy, but then a little voice spoke up from the back of my mind and said “Er, excuse me, but where does the diabolo go? And the diabolo handsticks? And the devil sticks, come to that. Also, the front swings open, weren’t you going to design some fancy closing mechanism that would ALSO hold the juggling rings?

Reader, I switched off the lights and left the workshop.

But a few days later I was back at it again, because my wretched brain could see POTENTIAL. This might actually be GOOD and IMPRESSIVE and lots of other concepts that really shouldn’t matter to me now that I am nearly forty nine and living on a different continent from most of the people who made me feel inadequate as a human being.

I shifted the knives over to the same side as the fireclubs, because there’s room for both and then they rattle less, and that made space for the diabolo and both sets of handsticks on the right.

The Devil Stick itself was too tall for the box. I didn’t want to cut holes in anything, so I bolted a small plastic holder to the bottom of the right hand side, and the last of my general purpose tool holders to the top. Click!

Now for the front. I cut a couple of blocks to the curve of the juggling rings, then glued them on either side of the front doors. Then I cut a couple of square blocks that were larger and glued them on those blocks. Now the rings would hook in on these blocks and sit snug, holding the doors closed!

I also dug out a small pair of wheels for the back and some rotating castors for the front. Now the front doors could swing open easily.

And that’s where I am now. The voices in my head have subsided a bit, apart from the one saying the box of balls needs to be secured to the main box, and the whole thing should be edged with veneer to hide the screws and then lacquered a deep honey gold. Oh, and there should be some sort of handle to pull the thing along. And where am I going to put the poi? And what about the buckets for the magic bucket trick?

I don’t know why zombies want brains. They’re nothing but trouble.

A perfectly useless hobby.

What are you supposed to do as a hobby when your real job is something other people do as a hobby?

When I was a kid, one of the things I wanted to do was work in the movies. Specifically, I wanted to work in Special Effects. Back in those days, that meant modelmaking, creating real props, and, occasionally, blowing stuff up.

When I was eighteen, I actually had the chance to visit a real effects workshop, and saw some of the machinery they had. They even owned their own fire engine to produce rainstorms when the weather wasn’t co-operating with filming schedules. More sobering was the owner’s right hand, missing two fingers after an effect went disastrously wrong.

But I didn’t get into the movie biz, and modelmaking does not suit my short attention span. Every model I make ends up looking like it was hit by anti-aircraft fire, even when they’re sailing ships.

Costume on stand

But the Cosplay bug bit a few years ago, once we had settled down into a house where I had a workshop to call my own. I made my Mandalorian helmet, using trial and error and error and error. Once I’d stopped working on that (not once I’d got it right…I’m fairly realistic about my efforts here) I decided to tackle the Scout Trooper Helmet.

I don’t know why I coveted this particular helmet. It’s probably because “Return of the Jedi” was the first Star Wars film I saw at the cinema, and the Speeder Bike chase scene was burned onto my brain ever since.

Remembering the frequent disappointments with the Mando helmet, I swore that this time I would take things slow. Not rush stages and spoil things.

I found an old ski helmet at a sports sale and decided to use it as the base for the helmet. Then I decided the two other main materials were going to be the foam flooring tiles available in stores everywhere ($11.99 for four) and lots and lots of filler. Filler can be bought in big tubs, it’s almost stiff enough to mould and hold a shape, and you can sand it smooth. If you have patience.

I cut a disc out of a flat piece of floor tile and settled it on the helmet, then replaced the disc to make the raised section on top. The side pieces are held in place by a foam insert (white). Filler round the top attempts to smooth things over.

I cut a disc out of a flat piece of floor tile and settled it on the helmet, then replaced the disc to make the raised section on top. The side pieces are held in place by a foam insert (white). Filler round the top attempts to smooth things over.

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I used some pipe insulation to make the raised section that goes from ear to ear around the back. This is the first place where careful measurement and symmetry comparisons would have been good.

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The “jigsaw” lines are the result of using the straight edge of the floor tile, then filling the gaps in the jigsaw edge with glue. Amateur mistake. The glue resists sanding, either sticking to the sander, or melting and flinging glue everywhere.

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As usual with projects like this, I can’t help spraying on some paint in the hopes it will start to look really good. It never does.

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Heavy application of filler begins to cover over the glue jigsaw disaster. I start to use the filler to flare out the “ear” portions. Again, I did this without carefully checking the various reference photos I have of the real helmet.

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I removed the foam inserts and immediately saw that I hadn’t got the front cut straight, or attached evenly. I SHOULD have taken it apart then and there. Instead I decided to try and press on and fix it as I went.

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I was quite proud of this front piece. After so long staring at the cowling, it was nice to see the face of the trooper helmet emerge. I cut the visor hole freehand, and did not use any measure referents. It is not even. I did have scalpel blades to cut the foam tile, but no scalpel to hold them in. This is not an optimal situation.

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Adding more filler helped the shape of the face plate, and emptied the filler tub. Please don’t imagine this is taking place in one or two extended sessions. Each advance takes place over five or ten minutes grabbed here and there amongst other adventures. On the plus side, this means the filler dries before I attempt to ruin the next bit.

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The faceplate is way too long, so I need to cut it down. Plus it doesn’t go all the way around to the back, so I have a piece to put in. I added the purple piece because it’s raised detail on the actual helmet, and I felt putting in a piece of thin foam would be easier than sculpting it in filler.

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This shows the gap at the back that needed sorting out.

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With the faceplate cut down, the helmet sits at a more pleasing angle.

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More filler and some determined sanding starts to get the right surface finish. I also cut and reshaped the corners of the cowl. It’s too high, but it’s the right shape.

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The reshaping has left one side looking oddly angled. Naturally, I tried adding paint to see if it helped. You can see how well that worked.

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Shaping the snout was moderately successful, and actually, adding more paint makes the whole thing look more of a piece. The contour lines running out from the snout are wrong though, and in remodelling I’ll get them wrong in a different way.

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When I found the visor material (an old school binder cover) I couldn’t resist sticking it in temporarily and trying it on. It’s hard to see through, steams up, and is impossible to take selfies in, because you can’t see what you’re doing.

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More sanding has improved the surface, but left the thing looking like it barely survived a fire.

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This shot shows how badly asymmetrical the faceplate is. A devoted cosplayer would either start afresh, or tear the helmet down a few stages. I tried adding more paint.

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Oh yes, that’s much…er…shinier.

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In the real helmet, that cut down the side is where the faceplate lifts up so you can put it on. That doesn’t happen with this one, but it still has to be there.

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Shots like this make it look pretty good. Mostly because they don’t include the reference photographs showing where I was going wrong.

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The surface of the snout wasn’t smooth enough, so I decided to add another piece of the thin craft foam. This picture is just checking the fit – I sprayed it black before gluing it in.

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Real dedication would have been continuing to sand and paint and sand and paint. But I lost all patience and glued the visor in instead. Now I couldn’t spray anymore, unless I went to the trouble of covering the visor. And you know how likely that is.

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Couldn’t resist trying it on. Vaguely reminded of Snoopy.

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With all work on surfacing pretty much abandoned, it was time to add on the little details. Measuring for pinpoint accuracy and comparisons with photo referents were just two things I didn’t do….

I added the "Enhanced comlink" piece to the bottom of the snout.

I added the “Enhanced comlink” piece to the bottom of the snout.

Now I needed the extra pieces to complete the snout. Here, measuring would be vital to get them looking exactly right.

Now I needed the extra pieces to complete the snout. Here, measuring would be vital to get them looking exactly right.

But unfortunately, I didn't do any.

But unfortunately, I didn’t do any.

WP_003656This whole project took around six months. Along the way, Mrs Dim reminded me that I’m not very good at this sort of thing, and I had a serious think about WHY I still do it. I can see the flaws in what I’ve made, even while I’m making it, but making it is something I enjoy doing. I don’t mind that I never get whole days to work on it. Probably wouldn’t enjoy it if I did. I know this is nothing like the 501st produce, but that’s ok too, because I don’t think I’m really doing this for the Cosplay aspect. It’s just something I do for me, something that isn’t writing, or cleaning, or cooking, or parenting. It may be less practical than knitting, less aesthetically pleasing than painting, but it’s my hobby.

Any suggestions for my next project? I quite fancy taking on a Clone Trooper helmet…..