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  1. Sixxgunn13's Avatar
    Member Since
    Mar 2002
    Posts
    1,585
    Jun 11, 2009, 3:05 PM - FPH, about to start. #1

    Hey Guys,

    Well I think it's about time I start on my FP helmet... Halloween is around the corner.

    I have a few questions on how some of you cut the slots in the back and visor area.

    I've worked on 2 Sgt. Fangs and they are easy to cut sand etc..etc. due to them being resin but fiberglass with gelcoat is different story.

    The reason I ask is when I drilled the holes for the metal ear pieces I had some chipping. Lets just say I don't want to run into any problems cutting fiberglass.

    So if anyone who has worked on a FP helmet, any advice would be appreciated, also what tools did you use.

    thx in advance.
  2. Jango's kid's Avatar
    Member Since
    Nov 2002
    Posts
    2,517
    Jun 11, 2009, 3:23 PM - Re: FPH, about to start. #2

    For the keyslots, I used a tiny metal etching bit with a dremel tool. They really are about the size of a pin head, but cut really well. The last time I did that with a FG bucket, was an MSH2, but I imagine the FPH is very similar. You won't be able to get them completely strait, so After i had them cut out, I took a thin steel shim, and taped fine sandpaaper to it, then sanded smooth. Worked pretty good.
  3. CombatBaby's Avatar
    Member Since
    Jul 2005
    Posts
    2,325
    Jun 11, 2009, 5:04 PM - Re: FPH, about to start. #3

    i haven't had a FPH but i've worked with fiberglass helmets before. I started with a dremel and finished off with filing....I don't think you should have trouble after that especially once you get primer on it.
  4. Timmer's Avatar
    Member Since
    Nov 2008
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    368
    Jun 11, 2009, 5:10 PM - Re: FPH, about to start. #4

    I did the dremel tactic to cut them, and to sand them I used files from a $15 multi-file kit from Home Depot. I finished it off with tongue depressors /popsicle sticks, that I glued various grades of sandpaper to. It made it very easy to sand.
    Last edited by Timmer; Sep 6, 2009 at 6:46 AM.
  5. Sixxgunn13's Avatar
    Member Since
    Mar 2002
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    Sep 5, 2009, 7:44 AM - Re: FPH, about to start. #5

    Well I decided to pick up where this OLD post ended off...
    Allot of new members on the board... I want to say Hello and welcome, this is the best Fett forum on the net.

    Well,
    Here are the pics of the helmet with all the openings finished, it took a while to cut, file & also sand the mold line.
    enjoy... Click on thumbnails to enlarge pics. :fett:
    Here is a front shot of the hemet with two of the aluminum ear pieces to see the over all shape.

    Here you can see how I drilled holes to start then filed it to the desired shape.

    Here I attached the aluminum ear to see how it would look.


    next post will be starting on filling pin holes and bubbles In the gel coat with putty, bondo and a coat of primer.

    Ill post more later


  6. Sixxgunn13's Avatar
    Member Since
    Mar 2002
    Posts
    1,585
    Sep 5, 2009, 7:48 AM - Re: FPH, about to start. #6

    I guess the Mods should move this to the Helmet section.
  7. I helped at SDCC '08 987654321a's Avatar
    Member Since
    Dec 2007
    Posts
    760
    Sep 5, 2009, 8:39 AM - Re: FPH, about to start. #7

    AHHH!! Me want!

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