Stormcrow 85's WIP: Boba Fett - ESB

I have not been sitting around I have definately been working on this thing a TON. I can't thank the template makers enough there is no way I would have been able to figure this all out myself.I am moving along trying to get at least the first coat of bondo on the helmet this weekend and finish up my gauntlets. I don't have a lot of how to right now. I am going to have a HUGE timelapse when I am done with this weekend. I will have to trim it down.

I am am pleasantly surprised with how it is going so far. It is very far from perfect, but I think I am going to be happy with it once I get done.

Here is where I am at.

1. Cut out the main helmet as shown in my last post
- There is a TON of cutting and try and be very clean with your cuts
- Go back with some sand paper afterwards and clean up your cuts if you want

2. Cut out the inner supports
- I used 12 pack soda boxes as I am a cheapskate and didn't want to use my 2mm card board
- The 12 pack cardboard is fine, but I should have made the top dome piece out of the 2mm card board then cut it down later
- Glue the inner supports together (I used hot glue)

3. Dampen and shape the inner surface
- If I were to do this again I would place the seam behind the ear plate which would just mean cutting out the template slightly different than the way I did it
- Use clamps and the inner braces to achieve desired shape, I turned it upside down so the top was on a flat surface
- Leave to dry (It was then I notice I put the top part "upside down" which means any "flare" irregularities in the helmet are are the wrong side

4. Apply the outer surface
- I left this to dry into the shape after I dampened it then came back and attached it
- I made a mistake at this portion: I used wood blocks to keep the pieces flush with each other and the helmet lost some of its correct shape
-- It isn't the end of the world, but it does throw the shape off just a little
- I chose Elmer's glue because it dries harder than hot glue
- I attached this in 4 separate glue sessions and I left it at least a half a day at each section, the main reason I did this is I only have 6 clamps and I seemed to use all of them in a small area: The order:
-- 1. Front
-- 2. Right Side
-- 3. Left Side
-- 4. Back

5. Cut out the cheeks and install the recessed cheeks
- This was a fiddly process I spent a couple hours molding these into place (It was also spent on the phone with my sister on her Bday!)
- I used hot glue for this portion I would suggest not cutting out the inner pieces until you shape the upper cheek portions in as there is some changes to make if you don't get the helmet shape perfect when you do it
- I also used some of the drying time to make a right ear piece

6. While you take a break go ahead and shape the dome pieces
- Moisten the parts and shape them into a semi-circle and I used a clamp along the top to force all the pieces to move into the center
- The dome is a pain
- Add the support rings to the bottom portion of the helmet


Step 3:
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Step 4:
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Step 5:
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Step 6:
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Some Gee whiz information about the video above.
The last video I put together was ~59000 pictures @ 1 Picture per second = 59000 Seconds or 16 Hours and 21 minutes.

This isn't all inclusive as there were many minutes edited out and the timelapse's were sped up in the final video even more, and I added an introduction and voice over.

What I am saying is this is time consuming. I am glad that I am documenting it all though!

Here is where she is at. Also i should have the next gauntlet video in the next few days I am almost done with them and they are looking pretty awesome (missing a few things from them though aka flamethrower! and keypad)

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hey stormcrow i make boba fett buckets/helmets...i have one that i just casted and it has a couple of minor flaws on the inside nothing wrong on the outside at all. I make these out of urethane plastic and are very durable. I will make you a great deal on it if you are interested in it. i just found this thread today you have been posting in. PM me if you are interested
 
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tommyboy, I PM'ed you. I will finish this scratch build but I am always interested
TK50175 Thank you very much. It is coming together, unfortunately with work, family, school, and lots more work, I am having a hard time devoting the time needed to get it done.

I didn't do much on the costume over the past few days, but I did get some work done on the gauntlets. I realized I painted them to dark, but they are going to stay that color I am not changing it now.

Since I last posted the gauntlets I have

- Added some weathering
- Added the right gauntlet darts and hose
- Painted the rest of the base colors

What I still need to call these complete is below

Left Gauntlet
- Make the left rocket gauntlet
- Make or buy the Keypad
- Make the Flame Thrower
- Make the Dental Expander Greeblie

Right Gauntlet:
- Probably going to remake the darts from Aluminium (so when the wood eventually breaks I will have replacements)
- Add the red and silver dental file pieces to the whipcord housing
- Add the middle section black greeblie (I have to make it first)
- Trim the hose

Then I think I can call them done! Here is where they stand. I have more video, but I have not created it yet so pictures only at this point.

Right Gauntlet:
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Left Gauntlet:
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Wearing them!
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My Favorite!
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I put in the wooden darts today when I put the gauntlets together and I thought "Man I like them" but the other day I picked up some aluminum rod. I will be attempting to turn quite a few of these aluminum darts out in the future, but I made one in my "home made" lathe AKA Cordless Drill in a vise. I think it turned out well and I figured people might want to know how I did it. Since this was a prototype I did not document it with video/timelapse like I normally do

What you need to make the below darts:
- Aluminum Rod at least 3mm in diameter
-- If you can find a 3mm diameter rod you will save yourself SO MUCH TIME
-- I just picked up this rod from home depot (they might have had a smaller diameter, but I didn't have my caliper on me to do measurements)
- A File
- Needle Files
- Hacksaw Blade
- Sand Paper (grits: 120, 220, 400, 500)
- A caliper tool to easily measure diameters

Step 1: Cut Rod to length
-- You could probably chuck a rod long enough to do all all the darts up and start at the far end then work your way back (or at least 2 darts)
-- Making 2 at once could save some of the material as you have to lose some to the drill chuck

Step 2: Size rod to correct diameter
-- I took the entire length to 3mm diameter

Step 3: Add point
-- File ~45 degrees, press it to the end, let it file as the lathe spins

Step 4: Make marks and cuts for the tip pieces
-- The tip is 5mm total from point to beginning of the 1.2mm wide recess
-- I made it with 2 valleys so if the point is 5mm overall that means ~.5mm from the back edge and another 1mm in front of that you want the detail valleys
-- Marking the 5mm back mark with a sharpie I went about a hacksaw blades width towards the tip and cut in the first recess
-- The hacksaw blade is very good for doing this as you hold it steady and let the drill do the cutting
-- Once the lathe gets the groove started you can move the hacksaw blad back and forth in a sawing motion to cut faster (be careful not to cut too deep)

Step 5: Cut out the valley that is 1.2mm in diameter (mine is probably closer to 1.5mm)
-- Again using the sharpie mark back from the 5mm dart tip another 7mm (it should be 12mm from the tip)
-- While the lathe is spinning use the Hacksaw blade to cut a valley at the 12mm back and the 5mm back from the tip these keep you from going to far with your file
-- I turned my flat file on its side to make it smaller and just worked it back and forth between the two initial cuts to create the valley
-- This took a little while and I measured often

Step 6: Sanding
-- I started with 120 then stepped through going 220, 400, to 500

Step 7: Admire your work.

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Thanks man. I am trying to make a lasting contribution to the community. I have always had a philosophy that I will show people how I do something. So when they go to do the same thing or something similar they can say "Well he did it like this, and it did/didn't work so I am going to do it the same/different way".

I swear my hard drives hate me. I have about 150 gigs of space that I am constantly filling up then having to delete. I just transferred 35 gigs today after deleting over 60 gigs of pictures and videos.

No pictures, but I went over to a buddies house and used his lathe to make a facsimile of the RKD and WoF flame throwers. I believe I made the tubes too small of a diameter, so I will have to do it all again soon to fix it, but holy cow are lathes fun! He has a small metal lathe that has adjustment knobs which make it very easy to recreate the same part several times! I want one SOOO bad!

Nicely done, look good pal (y) think this might be the most documented builed ever :eek:

Current Status of To Do List:
To Do:
1. Finish Gauntlets
-- Right Gauntlet 90% done
--- Need whipcord greeblies (have the parts need to sand and paint
--- Light Steel Wooling
-- Left Gauntlet 50% Done
--- Make Dental Expander greeblie
--- Make Gauntlet Rocket
--- Make Keypad
--- Make Flamethrower
2. Make Knee Armor
-- I have the templates I need to cut them out and shape them
-- Make the knee darts
-- Get the Straps
3. Make Shin Tools
4. Finish Flight suit:
-- Make Shin Pockets
-- Ankle "ties"
5. Paint Back Armor
6. Helmet
-- Cardboard Helmet 20% Complete
--- Need to Bondo Helmet and smooth
--- Need to get TVisor
--- Finish parts (Stock, range finder, left ear)
--- Paint
7. EE Blaster: 0% Complete
8. Pulce Side arm and Holster: 0% Complete
9. Hanging Side Pockets
10. JetPack
 
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Another video is up! I think this is the best one I have made today!

The Base coat was laid down in update 28. In this video I:
- Put on the silver base coat
- Put on the green top coat
- Put on the Black and White
- Added the Gauntlet Darts and the Right Gauntlet Hose
- Reconnected the switches to the LEDs



 
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I was out of town for two weeks, and I am still working on putting together the next video it should be the bondo process for the helmet. I have a couple more coats of bondo and subsequent sanding to do before I can make the video though. Here are some progress shots of work done the past couple weeks.

First a couple shots of the hose for the right gauntlet and the box for the part I used for the hose.
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The helmet is turning out pretty good I am going to have at least 2 or 3 more coats like I mentioned above, but I really like the shape the dome is taking. I am a bit worried the inside I did a thin coat of resin and it is still a little sticky almost a month later :(.

Also does anyone have any advice on whether to use rondo (resin and bondo) or just bondo for the final coat I would think the thinner rondo would go on more smoothely.
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The sanding continues. I also got a very cool thing in the mail this week! Check it out.

I finally made the left ear piece as well. So a third coat of Bondo is now on the helmet (waiting to be sanded off), and the left ear is made.

Thank you tommyboy for a rad helmet I am looking forward to putting it to good use!

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Thank you all for the kind words. I finally got the next video up, took me way longer than normal.

Here is what I did:1. Coat the helmet and ear pieces with polycrylic
2. Cut out visor slot
3. Coat helmet with Fiberglass resin (I should have done more)
4. Bondo the dome, cheeks, and ear pieces
5. Sand smooth (This involved small files and an assortment of sand paper grits)
6. Add hole for borden connector
7. Add dent



I still have many things to do, but I am going to add the first coat of primer hopefully this weekend and will see how she looks after!

 
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So a small update I put a light coat of primer on the helmet and I noticed quite a few flaws so I am going to have to do a bit more work before I say she is ready for paint. Ohh and I borrowed a buddies lathe to make my flame thrower, but first I attempted to make a few gauntlet darts. I failed miserably,but I am going to try again, I think I figured out what I did wrong. The top dart is my prototype dart I did in the drill with a file.

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Aluminum SUCKS for these gauntlet darts. I went ahead and picked up some 1/8" steel rod per someone elses suggestion (I will find you in a minute and tag you in this post). I turned out a set and am going to see if there is any interest out there for me to make a run of these things. Let me know. (Admin if it isn't OK to plug my for sale thread let me know and I will reword/remove any comments about it from this thread). I made the pieces out of 1/8 metal rod (3.175mm) and the middle part is 2mm versus the 1.2 that would be 100% screen accurate.

I still need to add the die details on the tip, but I really like the way they turned out.


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those turned out really well. About to start on my gauntlets, so all the pics of yours and step by steps are very appreciated.
 
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good that you decided to switch out the wood darts to steel darts, its the small things that puts the details in the gauntlet and make them stand out :D
 
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