The Flying Riever

 Work is progressing well on the riever. I am getting the hang of working with the thin ply and I am forming shapes that I thought would be impossible. Its like making a giant card cut-out and the finished pieces are strong and very light.
The trick seems to be to steam or soak the ply, tape it into the required shape, and then glue it when it has dried. I am using super glue and pop rivits and the strenghting the back of the join with expanding wood glue.

One of the rievers high boots. The toe cap is the only piece made from solid wood.
The breastplate was the most difficult piece to get right.
The legs fitted to a wooden support.This will be fabricated in steel tube later.The feet have been screwed onto the pedals.
The breastplate rests on the tube that acts as the leg pivot. It is supported just below the shoulders by the upright pole.
An access hole has been cut to allow for the fitting of the flapping cape mechanics..
The neck and head are pivoted, and both will move, operated by one of the legs
An extra piece has been added to the breast plate, using the card template to get the shape right.
The head with a wooden nose.
The helmet, with a card mock-up of the crest.
I rubbed wood filler over the paper mache and then sanded it to get a smooth finish. Later it will be given a few coats of gesso and sanded again
This is the mechanism that operates the eyes.
I have added two ears.
The gauntlets.Only the fingers are solid.

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Hi Troy. Steaming over my kettle works well. Then it's a case of gradualy bending the wood into the required shape. 

Looks great! Do you steam or soak the wood, or both? I would love to see or get more info of the process. All your work looks awesome, thanks for sharing.
Troy