1st Helmet Build (Cardboard Fett)

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Bebommib

New Hunter

• Apr 8, 2015

• #41

One more question. I found some acrylic blocks I could order online to try and carve down, but am wondering if I should get clear, or frosted. To me the pictures look like frosted would be the way to go but looking for some feedback on that.

Here is one of the sites I found that offer both options:
http://www.pennant.co.uk/buy-360-Acrylic+Blocks.html

And i know that is a UK site, but just an example

 

RafalFett

Well-Known Hunter

• Apr 8, 2015

• #42

This image of the Supertrooper helmets being built shows a clear perspex/plexiglass block with opaque sides (more likely the effect of cutting to size):



@terminal fettler does great job with the rangefinders and he also do the clear parts too, so if you need some, he is the best.

 

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Bebommib

New Hunter

• Apr 10, 2015

• #43

RafalFett said:

This image of the Supertrooper helmets being built shows a clear perspex/plexiglass block with opaque sides (more likely the effect of cutting to size):

View attachment 86860

@terminal fettler does great job with the rangefinders and he also do the clear parts too, so if you need some, he is the best.

Click to expand...

Thanks a lot rafal!! That clears some things up.



Update:

We both finally finished up all the pieces. Everything is still just put together as cardboard, and not perfected but all the parts are done!

I was impatient and took some pictures of my helmet with the pieces placed on using only a couple dabs of glue. (they are off again now to be finished) but I thought i would post those up!!




Also, here is a shot of one of the rangefinders (Sara's) before inserting the wires and fiberglassing. The hollow cuts are so that the fiberglass will be all the way through every layer of cardboard and take up the entire thickness for extra strength.



I will post more pictures like usual of everything we have done (in more detail) when I have time. It's another work weekend for now though so just putting up the exciting stuff!!

Also, today marks exactly one month since we began this project!

 

StevenBills

New Hunter

• Apr 14, 2015

• #44

That is looking great. I'm currently building up a cardboard Fett as well, and I just have a simple question (not the hijack the thread!). Do you put a second outer layer (on the front) on top of the first outer layer after the cheeks are glued in?

SB

 

RafalFett

Well-Known Hunter

• Apr 15, 2015

• #45

StevenBills said:

That is looking great. I'm currently building up a cardboard Fett as well, and I just have a simple question (not the hijack the thread!). Do you put a second outer layer (on the front) on top of the first outer layer after the cheeks are glued in?

SB

Click to expand...

You don't need a second outer layer if you used 2mm thick cardboard for your build.

 

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Bebommib

New Hunter

• Apr 15, 2015

• #46

StevenBills said:

That is looking great. I'm currently building up a cardboard Fett as well, and I just have a simple question (not the hijack the thread!). Do you put a second outer layer (on the front) on top of the first outer layer after the cheeks are glued in?

SB

Click to expand...

Nope, as rafalfett said, as long as you are using 2mm thick cardboard it should already be the perfect thickness. The inner layer/outer layer together should be about 4mm thick and the cheeks will glue in flush with the top of the outer layer.

 

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Bebommib

New Hunter

• Apr 15, 2015

• #47

Update:

We have been working on smoothing out all the ear pieces/rangefinder, and in the mean time I have been planning the circuit board for all the helmet electronics.
I will post pictures as soon as I can though I am working a lot again so sorry on the slow updates.

 

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Bebommib

New Hunter

• Apr 27, 2015

• #48

Update:

I am super sorry about the delay of updates on this project. We have definitely been working (still) on smoothing and finishing up the ear pieces/range finder the past couple weeks, but with work and other things getting in the way we are limited to less than an hour a day on average, not even.

We just recently found out that Sara got a job in Japan, so we will be moving there for a year in July. With real life things taking a toll and us having to plan for a major change (Minnesota to japan!) it's been hard to find time to work on our helmets. That doesn't mean I wont be keeping updated though, as soon as I have time I promise I'll post all the pictures I have taken and post our progress.

Also, while in Japan maybe I'll try and join a Japan 501st garrison, we'll see!!

 

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Bebommib

New Hunter

• May 5, 2015

• #49

It's been too long!!


I finally had some time to take come photos and put them up so here we are:


Here is my first "Finished piece" and what it looks like after plenty of thin layers of bondo followed by Gesso. It actually feels like plastic now its so smooth. Any little areas that look like bumps or rough spots are simply the result of multiple layers of primer.
Took days just for this one piece, but I like it!

View attachment 87936View attachment 87933View attachment 87934View attachment 87935View attachment 87937View attachment 87938

We fiberglassed the inside of our helmet domes also for added strength. We are planning to sand down the cardboard supports a bit also to save some weight. Plus with the fiberglass we shouldn't need them to be so thick anymore.

View attachment 87940View attachment 87941

Here are all of Sara's pieces so far:



And mine:



And we started doing some fiberglass and bondo on the dome starting from the top and going downwards. As you can see we aren't too far yet, but I'd rather go slow and carefully than rush it.

View attachment 87939

So that's what I got. If anyone has any opinions or you think something is wrong or off, please let me know, we would both really appreciate it!!

Thanks for stopping by!

 

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Bebommib

New Hunter

• Sep 29, 2015

• #50

Just an update everyone. I am currently living in Japan now and may be for up to 5 years, and we left our helmets back in Minnesota. I am thinking of starting up again building the armor and suit itself here in Japan. Will update when decided for sure!