thinking of making a bucket..

  1. #1
    Cod'ika's Avatar
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    thinking of making a bucket..

    out of aluminum,but ive never worked with aluminum and i was wondering if anyone knew what materials id need,besides gloves lmao no one wants to lose a pinky for being stupid lol but yeah any recomendations or advice?
    any help will be appreciated thanks everyone!

  2. #2

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    Re: thinking of making a bucket..

    I saw someone build their helmet using WOF templates and aluminum... I have seen it on the site... I am looking for it now. He printed the templates on paper ( i remember the pics had his cat helping!) and then traced them to aluminum. He made it look easy - but I am sure it was not. The cuts were very precise - he did a great job with it. I will look around for the thread...

  3. #3
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    lol thats what got me exited,i saw that off the mercs thread,looks so easy i just wasnt sure how to go about cuting it out and such

  4. #4
    A'den Kyramud's Avatar
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    Re: thinking of making a bucket..

    The problem with an aluminum bucket is the dome...using WOF templates, you have to get it perfect...

  5. #5
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    i was thinking of doing what darkside sith lord did and use and already formed helmet and modifying that to fit the rest or just being really precise when useing the WOFdome template lol

  6. #6
    A'den Kyramud's Avatar
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    Re: thinking of making a bucket..

    I'd make your dome with fiberglass, then use the aluminum for the rest...because getting the dome perfect out of aluminum is going to be killer hard...

  7. #7
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    lol that sounds like a good idea to me hopefully ill have this up and running soon

  8. #8
    A'den Kyramud's Avatar
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    Re: thinking of making a bucket..

    Cool!!! post lots of progress pics!!! can't wait to see how it turns out!!!

  9. #9
    dankenman's Avatar
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    Re: thinking of making a bucket..

    Guys! I saw this on a cartoon. It's easy, you just have a friend hit you on the head with a frying pan. It will bend into a perfect form around your head!


    Ok, don't try that.
    I would say find an already made helmet to take the dome from, or find something to modify. The whole idea of doing it in metal is because its metal! If you did part of it in fiberglass, it's just not the same.(not ripping your idea apart, A'den Kyramud) If you go metal, then take it all the way, IMO.

  10. #10
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    does anyone have an idea of how much aluminum im gonna need and what would work best to cut it with?

  11. #11
    Riceball's Avatar
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    Re: thinking of making a bucket..

    Cod'ika said: View Post
    out of aluminum, but I've never worked with aluminum and I was wondering if anyone knew what materials id need,besides gloves lmao no one wants to lose a pinky for being stupid lol But yeah any recomendations or advice?
    Any help will be appreciated thanks everyone!
    You're going to need some sort of form to hammer your aluminum on and shape into a dome. From what I've seen of armorers at work they typically use a log or piece of wood that has been dished out and they hammer the metal into the indentation to form the shape. Or you could try an English wheel but that might be a bit of an investment and looks to take a lot of skill to use properly. You'll also probably need some something to weld the pieces of the helmet together unless you plan on trying to forge it from a single piece of metal which might be a tad difficult to do. Latsly. you're also going to need a lot of patience since, from what I've seen, handworking metal is a very time consuming process.

    Best of luck on this project, if you do decide to go ahead with it be sure to post plenty of pics and keep us updated on your progress.

  12. #12
    A'den Kyramud's Avatar
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    Re: thinking of making a bucket..

    When you hammer a piece of metal, what you are actually doing is stretching the metal, and if you stretch it too much you end up punching holes in it with your hammer.
    I'd go with a multi-piece dome, like this:
    http://www.scandinavianheritage.com/...ing-helmet.gif
    It'd make the process much easier.

    Another idea I had was to use the WOF templates, cut out the metal, weld it together, grind off the excess, then polish...just a thought

    dankenman said: View Post
    Guys! I saw this on a cartoon. It's easy, you just have a friend hit you on the head with a frying pan. It will bend into a perfect form around your head!

    Ok, don't try that.
    I would say find an already made helmet to take the dome from, or find something to modify. The whole idea of doing it in metal is because its metal! If you did part of it in fiberglass, it's just not the same.(not ripping your idea apart, A'den Kyramud) If you go metal, then take it all the way, IMO.
    That's how I made my dome!!!
    Yeah, the fiberglass does defeat the purpose...:o

    I'm gonna love watching the progress thread for this!!!

    A'den
    Last edited by A'den Kyramud; Jan 29, 2009 at 9:58 PM.

  13. #13
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    lol its not confirmed yet but its looking like a possibility i think im going to use aluminum and maybe do stips of it for the dome,like uh how to explain this...im thinking of cutting two strips and arching them to make a skeletal structure for the dome and then maybe sintra pieces to fill it in and fiberglass and bondo to make it tougher....or i may just buy a bucket lol but i know for sure that i want to do this project but there are things i have to take into account:

    1. i have never worked with aluminum
    2. never used fiberglass
    3.never used bondo

    so im kinda S.O.L lol cuz i dont want to shell out the creds for the materials and waste it,make sense?
    but ive seen it done so i know it can be done,im planning on upgradeing my armor to metal thats my plan so i may start with the armor and go for the bucket last but ill let everyone know my plans!!!! if anyone else has any advise let me know im def gonna need help on this lmao im no Novall lol im a n00b to metal working haha

  14. #14
    dankenman's Avatar
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    Re: thinking of making a bucket..

    I didn't research it at all, but today at work, I went into the kitchen and saw a set of metal bowls that were "nested". basically 5 bowls, each one slightly smaller than the next. They were almost exactly the right shape, and a great variety of size. I"m sure there are other brands that could be even better. Just an idea...

  15. #15
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    ooo thats a good point dankenman now that im thinking bout it i think i do have a bowl or two thatll work thanks vod!!

  16. #16
    dankenman's Avatar
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    Re: thinking of making a bucket..

    ...and I just wanted to make some soup.

  17. #17
    A'den Kyramud's Avatar
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    Re: thinking of making a bucket..

    dankenman said: View Post
    ...and I just wanted to make some soup.

  18. #18
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    haha well ill be sure to make sure theres no soup in my bucket befiol i put it on but i can see how haveing a bowl as the dome may be usful in the future.......hmmmmmmmm muahahahaha!!!!!1

  19. #19
    CombatBaby's Avatar
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    Re: thinking of making a bucket..

    DO IT!!

  20. #20
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    haha do what? make the helmet or eat soup out of it?

  21. #21

    Re: thinking of making a bucket..

    Not to cut you down, but I wouldn't recommend trying to build a helmet out of aluminum unless you've had a good bit of experience with it.

    Aluminum will be very difficult to make the curves with properly. It's not like you can just buy a few for sale signs and cut them up; aluminum is a metal, and metals are more expensive than wood, Sintra, and cardboard. You're probably talking about 1/32" aluminum sheet here; 1/16" will just be too thick for you to work with, barring proper metal shop equipment

    You'd be better off making a dome out of something else rather than try to form aluminum. As for the rest of the helmet, the complex curves will be difficult to match exactly; not that it can't be done, but it requires a LOT more work, since it's a lot harder (and more expensive) to fix bad bends in aluminum than cardboard/Sintra.

    While we're on the subject, how exactly are you planning to connect the pieces? You can't arc weld aluminum, you need a MIG or TIG welder to do it properly (if I remember right), and I wouldn't count on Bondo to actually hold well. Cutting the material is another problem; you can do it cheaply with aviation snips (which will distort the edges), and the best way to do it is with a press brake or plasma cutting system.

    I would go into detail and tell you which aluminum alloys you should be considering, but I'm not convinced that you should be trying this without a lot more knowledge of metalworking and forming.

  22. #22
    Cod'ika's Avatar
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    Re: thinking of making a bucket..

    and your probably right and im not going to try this ATM but this is on my TO-DO list of things i want to make,trust me there is a list and it rivals the naughty-nice list of santa lmao

  23. #23

    Re: thinking of making a bucket..

    It is very hard to do unless your a tin smith ive tryed with very disapointing results. how ever i got good results in the end buy ussing thing gauge aluminium rolled and glued plastic, for the back and the upper and lower checks. But good luck with it.

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