by Robert Merrill

I wanted to build a worn and weary Zaku. Something that has been in use, seemingly, forever.

So, with that in mind I started distressing parts. I started by working from the older, less visible damage out. Using a Dremel I ground out hollows in the plastic to give the look of repeatedly dented metal. I finished the dents with sanding sticks and polishing material. Then came the more recent dents and gouges. Again the Dremel was my best friend. Using a variety of bits I did smaller, sharper dents and larger gouges that I softened with the sanding sticks. A few of the dents where achieved with a light application of heat and some tools. Then finally came the bullet holes. I used a dental bit to make the initial divot and then used an Exacto blade to pick out the metal fractures. And more sanding.

I think I sanded my fingertips off.

I added some makeshift plates with .015 stock and GrantLine bolts & rivets. Some plates were welded on using some Tenax and an Exacto blade to make the weld bead.

Then came paint.

My first paint test produced great results. What I did was paint the part flat black and then mask off the damage and edges with salt. Then I applied two coats of paint and removed the salt. Then, I painted flat black again, followed by another salt mask and the painting with final color. This produced a look of repeated paintings with a subtle layered look that looked phenomenal, especially when the RustAll No.1 was applied.

The problem was all that masking and painting took too long considering all the parts involved. So I eliminated the under-painting and just did a single masking step. I lost some of the subtlety but it wouldn't take me 2 months to paint. Once the parts were painted the rust was applied. Generally 3 coats (the more coats the heavier the rust) but less on the weapons and more on the lower legs & feet. Oh, forgot the decals. Really, I did. This required a spot gloss coat, to avoid damaging the rust. I used some custom decals I had laying around along with deals from the Starship Modeler store. All were distressed then matte coated and more rust applied.

Then, finally, I got to dry brush it, add soot & oil stains and I was done.

I am so tired.

Oh, wait I still have a base to build, so much for sleep.

The base was built using scrap parts, Aves, MagicSmooth, rocks, dust, you name it. It received a mottled paint of tan & buff with the metal parts picked out in dark gray & black. Several washes were applied, the metal parts getting a serious dose of RustAll. Then finally a gentle drybrushing of light tan.

Image: Left side

Image: Right/front view

Image: From behind

Image:Right side

Image: Detail, left/rear torso

Image: Detail. left/front

Image: Detail, left leg

Image: Detail, weapons

Image: Right hand

Image: Detail, right leg

Image: In the spotlight