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Frown

 

 

Decals installed

Here's where to cut
Green is the first method I used.

I started to cut the  indented portions of the frown by using the smallest drill bit I had with my dremel.  I used it to poke many small holes in each spot & then using a larger cutting bit to cut them out.

I that point I realized that I should probably be using the included decals as a template.  Using far too much windex(just a light spray will do), & sprayed the frown, & temporarily attached the the decals.

As shown in the pic on the left, I then simply dremeled some very small holes in the corners of the black sections on the decals.

Rough cuts made.Dremel bit I then removed the decals & used a hi-speed cutting bit in my dremel to come as comfortably close as I could to the marks I made.  BE CAREFUL when using the dremel, because it can jump on you!
Frown cut & filed down After dremeling it pretty close, & found some metal files in the basement.  I used these to square the cuts up a bit.
Mask the frown After cutting out the frown I masked off the area I wanted to paint gray.  I used the included decal as a guide, along with electrical tape, masking tape, &  paper bag.(I learned my lesson from the newspaper!)

I finally found a good gray paint at Menard's!

Masked AND painted Once the frown is properly masked off, it's simple work to spray paint it.
Painted! And voila!!

I have to touch a few spots up, or not. :)

Since we've poked big holes in the frown, we must cover it somehow without blocking all airflow.(that IS why we cut the holes to begin with.

I bought a screen patch kit & painted it black.

Next hot glue some behind the vents.  I glued them at an angle simply because I thought it looked nice.  I'd never used hot glue before, & I think I might have used too much.

TIP: Hold a damp cloth on the front of the armor, behind the spot you're gluing.  The heat from the glue can warp the ABS!

After one layer, the frown was still fairly easy to see through from certain angles, so I added another layer of screen.
This time I placed it straight on (90 degrees rotated from before) & it looks MUCH better from the outside than from the inside. :)
 

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Last modified: May 09, 2005